SERVICE MANUAL - westerbeke.com manual/52089_rev2_3.0bpmg... · service manual 3.0 bpmg and 3.0 bcg...

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SERVICE MANUAL 3.0 BPMG and 3.0 BCG

60 and 50 HERTZ SINGLE PHASE

GASOLI

REVISION 3 APRIL2018 l..,,_, 'WES12RBEKE

j WESTERBEKE CORPORATION• 150 JOHN HANCOCK ROAD I MYLES STANDISH INDVSTRIAL PARK• TAUNTON MA 02780

WEBSITE: WWW.WESTERBEKE.COM

§Jf',d'f Member National Marine Manufacturers Association _.,,..,,

AwARNING

Exhaust gasses contain Carbon Monoxide, an odorless and colorless gas. carbon Monoxide is poisonous and can cause unconsciousness and death. Symptoms of Carbon Monoxide exposure can include: •Dizziness • Throbbing in Temples •Nausea •Headache

• Muscular Twitching •Vomiting

• Weakness and Sleepiness •Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical attention. Shut down the unit and do not restart UJJfil it lu!s 'Hen inspected and repaired.

A WARNING DECAL Is provided by WESTERBEKE and should be fixed to a bulkhead near your engine or generator. WESTERBEKE also recommends installing CARBON MONOXIDE DETECTORS in the . WARN ING living/sleeping quarters of your vessel.

·. They are inexpensive and ea5ily ~~~~oE obtainable at your local marine store. ~~

CALIFORNIA PROPOSITION 65 WARNING

Marine diesel and gasoline engine exhaust and some of its constituents are known to the State of California

to cause cancer, birth defects, and other reproductive harm.

TABLE OF CONTENTS

Parts Identification ... : ......................................... 2

Testing for Overhaul ····························~··············.3 Troubleshooting.Guide ........................ : .............. .4 Disassembly Procedures ..................................... 6 Sealants and Lubricants ..................................... 7 Torque Specifications ..................... , ................... 9 Speci.al Tools ...................................................... 11 Service Standards/Repair Limits ...................... 12 Engine Disassembly ........................................... 15 Inspection and Measurement ........................... 20 Engine Assembly ............................................... 27 Oil Pump ............................................................. 32 Lubrication System ............................................ 32 Fuel System ....................................................... 33 Fuel Filter/Fuel Pump ....................................... .33 Starter Motor ..................................................... 34 Carburetor .......................................................... 35 Raw Water Pump ............................................... 36 Engine Tuning .................................................... 38 Engine Adjustments ........................................... 39

Compression Test ........................................ 39 Water Pump Belt.. ....................................... .39 Ignition Timing ............................................ 39 Oil Pressure Test.. ....................................... .40 Spark Plugs .................................................. 41 Thermostat ................................................... 41 Choke Solenoid ........................................... 41 Valve Clearance .......................................... .42 Timing Belt Replacement/ Adjustment.. ..... .43

Electronic Governor .......................................... .44 Wiring Diagram ................................................. .45 Specifications .................................................... 46 AC Generator ..................................................... 47 BC Winding Resistance .................................... .48 BCG Internal Wiring Diagram ........................... .48 By passing the Overspeed Board ..................... .48 BCGJBPMG Troubleshooting Chart ................... .49 Flushing the Cooling System ............................ 50 English to Metric Chart.. ................................... 51 Standard Metric Conversion Data ..................... 52 lndex ................................................................... 53

Engines & Generators

1

16tllTJON CONTROL MODULE

GENERATOR TECHNICAL DATA LABEL

START/STO.,.,..,.. SWITCH

IGNITION COIL

EXHAUST CONNECTION TO MUFFLER

EXHAUST

FUEL PUMP

PARTS IDENTIFICATION

ENGINE SERIAL NUMBER

MAGNETIC PICK-UP

CIRCUIT BREAKER 2bA FUSE BATTERY CHARGING

FRESHWATER (COOLANT) MODEL

10A FUSE

ENGIN. E SERIAL\ NUMBER

BATTERY --=--'t---1 VOLTAGE REGULATOR

IGNITION COIL

THERMOSTAT

SERVICE SIDE UHAUST

--'TEMPERATURE !SWITCH

---._,OIL FILTER

SIPHON BREAK 'CONNECTION

COOLANT PRESSURE C,l\P

GENERATOR

ACTUATOR

LEFT SIDE

ISOLATOR MOUNT

ARBURETOR

COOLANT PUMP

WATER INJECTED EXHAUST ELBOW

WATER (COOLANT) TEMPERATURE SWlfCH

r;-~--- OIL DRAIN HOSE

----HEAT EXCHANGER

SERVICE SIDE

RAW WATER PUMP

. JL SUMP

DRIP PAN

WESTERBEKE Engines & Generators

2

TESTING FOR OVERHAUL

HOW TO DETERMINE ENGINE OVERHAUL PERIOD Cause of Low Compression Generally, the time at which an engine should be overhauled is detennined by various conditions such as lowered engine power output, decreased compression pressure, and increased fuel and oil consumption. The lowered engine power output is not necessarily due to trouble with the engine itself, but is sometimes caused by improper oil, clogged filters or a faulty carburetor. The decrease in compression pressure is caused by many factors. It is, therefore, necessary to determine a cause or causes on the basis of data produced by periodic inspection and maintenance. Oil analysis on a seasonal basis is a good means of monitoring engine internal wear. When caused by worn cylinders or piston rings, the following symptoms will occur:

1 Low engine power output 2 Increased fuel consumption 3 Increased oil consumption 4 Hard engine starting 5 Noisy engine operation

These symptoms often appear together. Symptoms 2 and 4 can result also from improper fuel regulation or a faulty carburetor. They are caused also by defective electrical devices such as the battery, starter or spark plugs. Therefore it is desirable to judge the optimum engine overhaul time by the lowered compression pressure caused by wont cylinders and pistons plus increased oil consumption. Satisfactory combustion is obtained·only under sufficient compression pressure. If an engine lacks compression pressure, incomplete combustion of fuel will take place even if other parts of the engine are operating properly. To determine the period of engine overhaul, it is important to measure the engine compression pressure regularly. At the same time, the engine speed at which the measurement of compression pressure is made should be checked because the compression pressure varies with engine rpm. The engine rpm can be measured at the front end of the crankshaft.

NOTE: To test engine compression see the ENGINE ADJUSTMENT section of this manual.

3

OVERHAUL CONDITIONS Compression pressure tends to increase a little in a new engine until piston rings and valve seats have been broken in. Thereafter, it decreases gradually with the progress of wear of these parts.

When decrease of compression pressure reaches the repair limit, the engine must be overhauled.

The engine requires overhaul when oil consumption is high, blowby evident, and compression values are at minimum or . below. ···

TROUBLESHOOTING GUIDE 3.0 KW BPMG When toubleshooting indicates an electrical problem, see the ELECTRICAL SYSTEM WIRING DIAGRAM, as this may reveal other possible causes of the problem which are not listed below.

PROBLEM PROBABLE CAUSE

Engine does not 1. Voltage drop at starter solenoid crank. terminal.

2. Main 10 amp fuse blown. 4. Battery is low or dead. 5. Loose battery connections. 6. Faulty wire connection. 7. Faulty start switch. 8 Faulty pc board

9. Faulty starter solenoid 10. Water ftlled cylinders.

Engine starts, runs 1. Faulty shutdown switch,( oil pressure, and then shuts or exhaust temperature). down. 2. Faulty overspeed switch.

3. Dirty fuel/water separator filter. 4. Clogged fuel line. 5. Low oil level in sump. 6. Faulty fuel pump. 7. No fuel 8. Clogged fuel filter

Engine starts, runs 1. Faulty mag-pickup sensor. but does not come 2. Electronic governor controller faulty, up to speed. 3. Fuel pump.

4. Fuel supply to engine restricted. 5. Actuator linkage binding. 6. Actuator or electrical connections

faulty. 1. Air intake restricted. 8. Exhaust restricted.

Engine cranks but 1. Out of fuel. fails to start. 2. Engine is flooded. (Engine will crank 3. Faulty carburetor. (See Carburetor page) for 15 seconds) 4. Faulty choke solenoid

5. Faulty ignition coil. 6. Bad spark plugs

Engine hunts. 1. Controller gain adjustment needed. 2. Faulty fuel pump. 3. Faulty PC board. 4. Improper drive belt tension. 5. Low DC battery voltage. 6. High exhaust back pressure. 1. Dirty fuel filter 8. Generator overload. 9. Valves need adjustment.

The following troubleshooting tables are based upon certain engine problem indicators and the most likely causes of the problems

PROBLEM

Engine misfires.

Engine backfires.

Engine overheats.

Low oil pressure.

High oil pressure.

No DC charge to the starting battery.

PROBABLE CAUSE

1. Poor quality fuel. 2. Faulty ignition control module. 3. Dirty flame arrester. 4. Faulty ignition wires. 5. Spark plugs are worn. 6. Binding actuator linkage. 7. High exhaust back-pressure. 8. Valve clearance'S are incorrect. 9. Valve clearances are incorrect.

1. Faulty ignition control module. 2. Incorrect timing. 3. Engine is flooded. See Engine is

flooded under Engfne cranks but fails to start

4. Dirty flame arrester. 5. Faulty ignition coil. 6. High exhaust back-pressure.

1. Blockage in cooling water flow: inspect the raw water intake, intake strainer, pump impellers, and look for broken or seperated hoses.

2. Belts may be loose or broken. 3. Obstructed by-pass hose.

1. Low oil level. 2. Wrong SAE type oil in the engine. 3. Oil diluted with fuel. 4. Relief valve is stuck. 5. Faulty oil pump. 6. Faulty engine bearings. 7. Boat heeled over too much. 8. Faulty oil filter.

1. Dirty oil or wrong SAE type oil in the engine.

2. Relief valve ;s stuck.

1. Faulty connections to battery charging control.

2. 20 amp fuse blown/faulty. 3. Faulty voltage regulator. 4. Faulty magneto.


4

TROUBLESHOOTING GUIDE 3.0 KW BPMG PROBLEM

Blue Exhaust Smoke Discharge from the Engine

Black exhaust smoke Discharge from the Engine

Poor performance at generator speed

Starter stays energized after start

Unit starts and runs at idle speed

Note: MPU voltages to PC board: Cranking: 1.5 - 2.0 VAC Running: 4.0 - 5.0 VAC (2200 rpm)

PROBABLE CAUSE

1. Lube oil is diluted. 2. High lube oil level. 3. Crankcase breather hose is clogged. 4. Valves are worn or adjusted incorrectly. 5. Piston rings are worn or unseated.

1. Dirty flame arrester. 2. Faulty carburetor. 3. Idle mixture jet too rich. 4. Accelerator diaphragm leaking. 5. Valves are worn or incorrectly adjusted. 6. Piston rings are worn or unseated.

1. Contaminates in carburetor. 2. Faulty fuel pump/contaminated. 3. Electronic governor controller needs

adjustment.

1. Faulty MPU suspected. Check MPU. 2. Faulty starter solenoid.

1. Check MPU signal. 1.5 - 2.0 VAG cranking. 2. Faulty overspeed board.


5

DISASSEMBLY I ASSEMBLY PROCEDURES DISASSEMBLY • Before disassembly and cleaning, carefully check for

defects which cannot be found after disassembly and cleaning.

• Drain water, fuel and oil before disassembly. • Clean or wash the engine exterior. • Do not remove or disassemble the parts that require no

disassembly. • Perform disassembly in a proper order using proper tools.

Keep disassembled parts in order. Apply oil when necessary. Take special care to keep the fuel system parts from intrusion of dust and dirt.

• Parts must be restored to their respective components from which they were removed at disassembly. This means that all parts must be set aside separately in groups, each marked for its component, so that the same combination or set can be reproduced at assembly.

• Pay attention to marks on assemblies, components and parts for their positions or directions. Put on marks, if necessary, to aid assembly.. .

• Carefully check each part or component for any sign of faulty condition during removal or cleaning. The part will tell you how it acted or what was abnormal about it more accurately during removal or cleaning.

The parts assembled with the silicone can be easily disassembled without use of a special method. In some case however, the sealant between the joined surfaces may have · to be broken by lightly striking with a mallet or similar tool. A flat and thin gasket scraper may be lightly hammered in between the joined surfaces. In this case, care must be taken to prevent damage to the joined surfaces. For removal of the oil pan, use a special "oil pan remover".

ASSEMBLY • Wash all parts, except for oil seals, 0-rings, rubber sheets,

etc., with cleaning solvent and dry them with pressure air.

• Always use tools that are in good condition and be sure you understand how to use them before performing any job.

• Use only good quality lubricants. Be sure to apply a coat · of oil, grease or sealant to parts as specified ..

• Be sure to use a torque wrench to tighten parts for which torques ·are specified.

• When the engine is assembled, new gaskets and 0-rings must be installed.

Surface Preparation Thoroughly removes all substances deposited on the gasket application surfaces using a gasket scraper or wire brush. Check to ensure that the surfaces to which the silicone gasket is to be applied is flat. make sure that there are no oils, greases and foreign substances deposited on the application surfaces. Do not forget to remove the old sealant that remains in the bolt holes.

GASKET INFORMATION The engine has several areas where form-in-place RTV silicone gaskets are used such as LOCTITE 598 or GE RTV 100. To ensure that the gasket fully serves its purpose, it is necessary to observe some precaution when applying the gasket. Bead size, continuity and locatiO\ are very important. Too thin a bead could cause leaks and too thick a bead could be squeezed out of location causing blocking or narrowing of the fluid feed lines. To eliminate the possibility of leaks from a joint, it is necessary to apply the gasket evenly without a break while observing the correct bead size. The gasket material used in the engine is a room temperature vulcanization (RTV) type and is supplied in a 14oz ( 400 gram) applicator/tube. The RTV hardens as it reacts with the moisture in the atmospheric air and can be used for sealing . both engine oil and coolax;it assemblies.

6

APPLICATION OF SEALANTS AND LUBRICANTS· ..

<I> Ill al

Items e! .~ (!l c:

E al Ill iii <I> .2 .c Q)

-c Q) .c 0 I/) .t! < :a ..... :E Q) Q)

Ill Q) .... co ta -cc c: Remarks ::J e! Ill c 0 0 Q) c8 g "O "O O"O "O (!l ~ !1 .... (!l ::J:= c: c: <I> c: c Q) 8.cn 0 0 co 0 i

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~ s~ ~ <I> 1il c: Ill c: o,l!l t---i .t: "O 0 ' ~ w ~ .~ ~ 0 :; :J2 0 Q)

Parts Name c: ;;:: =~ ~ .c <11.c

~ 3 0 Ill

~ 8 iii u I- ..51- Ill -= (!l .,,. I/) 0-, .3

1342 13738 1741 12078 518 017 ~-64 5900

Cylinder liner • Inside wall

Piston • Ring groove, Periphery

Piston ring • Periphery

Piston pin • Periphery

Connecting rod • Inside big and small ends

Metal {Cylinder block, crank case) • Both sides

Crank shaft (thrust place) • Sliding surfaces

Crank shaft oil seal • Lips

Crank case cylinder mating surface • Joint part

Valve (IN, EX) • Shaft, Stem head

Valve stem seal (IN, EX) • Lips

Retainer • Complete

Valve spring seat • Complete

~ Valve spring • Complete () 0

::ci Camshaft • Bearing, cam Q) c Camshaft oil seal • Lips 'C> c w Cam pulley bolt • Thread

Rocker arm • Bearing, Slipper

Rocker arm shaft •. Shaft, side

Tappet adjust screw • Complete

Washer (rocker arm, t=0.5)' • Complete

Washer (rocker arm, t=2.5) • Complete

Spring drocker arm, free length 30 mm an 51 mmj_ • Complete

Fuel pump • Periphery of 0-ring, end of ..Q!ur!.Q..er

2ml at Suction port and Oil pump • discharge port , Boss part

0-ring

(81.5-10.7) • Oil pump 0-ring {"1.5 - 8.5) •

(81.5 - 15.5) • Oil pressure switch • Thread

7

APPLICATION OF SEALANTS AND LUBRICANTS

(!)

"' m Items ~

Q) (!) 'E .::: E ID

"' (ij (!) =i .r: ~

Q)

"O (!) 6 en < "' _J ~ Q) (!)

"' m (!) ..., Ill :a "O c: c: Remarks =i Q)

l(l c: 0 6 (!) 5g 0 ,_ .!!! g "O "O O"O "O (!) ,_ (!) c: c: <D c: c ~ Q) o·-"' J2 a.en iii 0 0 co 0 "O 'iii .E "O

OJ OJ .s OJ Ill Ql (!) ~ Q) C> Q) E ::Ol

(!) <D c: <D Q) (!) 1il c (/) c !5 O,l!l t---1 E: ~ ID Ql !£

.t "O :; 0 J2 m LU (.) (!) .,

Parts Name ~~ t) c:

~ ~ (!)

o~ ·" F F F .3 0 (/) 0 t5 0. t>

!II -= (.) (!) '<!" en .3

1342 137.lB 1741 1207B 516 G17 KS-64 5900

Oil filter • Seal

Oil filter bolt • Thread

Plunger ass'y • Inside (Pour 1 ml) ~1 .

Filter cap, 0-ring • Periphery

Solenoid switch • Terminal

• Spark plug insertion part Spark plug cap

.:x. • High tention cord (.) 0

::0 • Termini;i.I Q) Starter motor c: • Spread at pinion part slightly ·ai c:

Bolt and screw for Reef w • Starter case Friction plate, reel shaft part, • Spiral spring, rachet

Starter seal rubber • Engine oil • Oil; at oil change 1 OOOml

at overhaul 1200ml

Oilpan gasket • Bolt (upper pump case) • Thread

Upper pump case • Impeller sliding surfaces Joint part for water pipe guide

E_ngines_.& G.enerators

8

TORQUE SPECIFICATIONS

Item Thread size Bolt or Nut Tightening Torque

N-m kg-m lb-:-ft

MS x 1.25 Bolt 2S-30 2.S-3.0 20-22 Cylinder Block - Cylinder Head

MS X 1.0 Bolt S-10 O.S-1.0 5.S-7.2

Ms x 1.25 Bolt 23-25 2.3-2.5 17-1S Cylinder Block - Crank Case

M6 x 1.0 Bolt S-10 0.8-1.0 5.S-7.2

Connecting Rod M7 x 1.0 Bolt 11-13 1.1-1.3 S.0-9.4

Tappet Lock Nut MS X0.75 Nut S-8 O.S-0.8 4.4-5.8

Flywheel Cup M1S x 1.5 Nut 70-90 7-9 51-65

Drive fTimlng) Pulley M2S x 1.0 Nut 34-3S· 3.4!1·3.6 25-26 Engine

Driven (Camshaft) Pulley M6x1.0 Bolt 10-12 1.0-1.2 5.S-S.7

Plunger Assembly M16 x 1.5 - 19-21 1.9-2.1 12-15

Oil Filter M20 x 1.5 - 18 1.S 13

' Oil Pressure Switch PT1/S - 7-9 0.7-0.9 5-6

Cylinder Head Cover M6x1.0 Bolt 8-10 0.8-1.0 5.S-7.2

Inlet Manifold M6 x 1.0 Bolt S-10 0.8-1.0 5.8-7.2

Spark Plug M12 x 1.25 - 15-20 1.5-2.0 11-15

Engine Assembly MB x 1.25 Bolt 29-31 2.9-3.1 21-22 ' ~ ~"'! .

. . . -"···

'\

9

REQUIRED TOOLS

)&~~ ~ ~ ~ ~~·~> ~~~~

17

IS

~

v 1. Straight-point screwdriver (200 mrri)

- do. - (150 mm)

- do. - (100 mm)

2. Phillips screwdriver (20,0 mm)

- do. - (150 mm)

- do. - (100 mm)

3. Set of wrenches (6 pieces)

4. Box wrenches (10 x 13)

- do. - (17 x 21)

- do. - (21 x 23)

5. Adjustable wrench (300 mm)

6. Pliers

7. Needle-nose pliers

8. Snap ring pliers

9. T-bar, socket wrench ( 1 O mm)

- do. - (12 mm) - do. -

- do. -

(13 mm)

(17 mm)

10. T-bar universal wrench (10 mm)

- do. - (12 mm)

- do. - (13 mm)

11 . Plastic hammer

12. Hammer

13. L-shape hexagon wrench (8 mm)

- do. -, (10 mm)

14. Box wrench (16 mm)

15. Socket wrench (16 mm)

16. Torque wrench ( 100 N - m)

- do. - (12 N - m)

- do. - (5 N - m)

Pre-setting type box torque wrench

(10 mm, 7N - m) .... for the tappetlock nut

17. Socket wrench set

Engines & Generators . ·10

USING SPECIAL TOOLS

5. How to Use Special Tools 1. Flywheel cup puller

CD When disassembling

Fasten the tools ®and Sto the flywheel with

the bolts ~ and remove the magneto nut

(right-hand screw) with the socket wrench of

the correct size 24.

Next, screw tool O into tool 8 and tighten 0

with the socket wrench of the correct size 24.

The flywheel can be removed. Be sure to

use· bolts (D). /;\

c--:.'~/· 2? @;© ~i

@When reassembiing

Before replacing the flywheel make sure that

the magneto key has properly been set. After

setting the washer and nut on the crank shaft,

fasten tools@and e>to the flywheel and tighten

the nut.

Tightening torque: 70-90 N-m (7.0-9.0 kg-m)

(51-65 lb-ft)

2. Piston pin tool

After removing the piston pin clip, insert the tip of

the piston pin tool into the piston pin hole and

lightly tap the other end of the tool with a hammer.

Hold the piston with your hand to prevent damage

to the connecting rod. (When inserting the piston

pin again, take the same care as removing.)

Piston pin

Piston pin tool

3. Piston slider

This tool is to be used for inserting the piston into

the cylinder. After inserting the piston into the

tapered end of the piston slider, set the piston

slider together with the piston tightly on the top of

the cylinder and insert the piston into the cylinder

by pushing the piston crown 'with fingers.

Note: Don't stop inserting the piston into the cylinder until all the piston rings enter the cylinder.

Piston slider

.. Top of cylinder


11

SERVICE STANDARDS/REPAIR LIMITS/MAINTENANCE Part Name Check/ln~ct Standard Value/Maintenance R~airlimit

Cylinder Head 1. Carbon deposit on the combustion 1. Remove carbon deposit and clean. chamber

2. Scratch depth and distortion of the 2. Scratch depth or distortion is 0.1 mm (0.004in) 2. Repair (set #240·#400 sandpaper mounting surface. or more. the surface plate and polish the

surface for repair. Use #600 sandpaper for finishing).

3. Corrosion in the mated surface. 3. Repair or replace depending on the situation. 4. Clogged cooling water passage. 4. Clean and remove foreign matters.

Cylinder 1. Deposit in the water jacket. 1. Clean and remove foreign matters. 2. Wear of the inside cylinder 2. 59.00mm (2.322Bin) 2. 59.06mm (2.3252in) or more

diameter. Measure the bore with (If wear is exceeding the repair limit, a cylinder gauge replace or bore the cylinder and finish

by honing. Over-sized piston is 0.5mm. refer to item 4).

3. Seizure 3. Replace or use an over-sized piston after boring the cylinder.

4. Scratch and wearing down in the 4. When the liner cannot be repaired by means 4. Bore and hone&o 059.5K0.01mm cylinder liner. of #400-#600 sandpaper because it is (02.3425 ± 0.0 04in).Use oversize

extremely scratched or scored, or the piston and rings. difference between the max~mum wear and minimum wear is 0.06mm (0.0024in) or more.

5. Mating surfaces of the cylinder and 5. When the depth of scratch or distQrtion 5. Use #400 sandpaper on the surface cylinder head. in/of the mating surface is 0.1 mm (0.004in) plate and polish the surface. Use #600 or more. sandpaper for finishing.

Piston 1. Outside Diameter 1. Diameter: 58.960mm (2.3213in) 1. Outer Diameter: 58.90mm (2.3189in) or more.

a) Measure the diameter at a point 7mm above the lower end of the piston skirt.

b) Piston Clearance b) Piston clearance: 0.020-0.055mm b.) Piston Clearance: 0.15mm (O.OOOB-0.0022in) (0.0059in) or more

2. Carbon deposit on the piston crown 2. Remove carbon residuum and clean. and in the piston ring groove.

3. Scratch on the sliding surface. 3. Repair with #400·#600 sandpaper depending on the situation.

4. Measurement of clearance between 4. Top: 0.04-0.0Bmm (0.0016-0.0031in) 4. Top: 0.10mm (0.004in) or more the piston ring and ring groove. 2nd: 0.03·0.07mm (0.0012·0.002Bin) 2nd: 0.09mm (0.0035in) or more

Oil: 0.01-0.1Bmm (0.0004 - 0.0071in) Oil: 0.21mm (0.0083in) or more NOTE: To be replaced with a new oil ring, when replacing with new top and/or second rings. Sandpaper means water proof paper.

5. Measurement of diameter of the 5. Clearance between pin and hole 5. 0.04mm (0.0016in) or more piston pin hole. Loose: 0.002-0.012mm (0.00008·0.00005in)

Piston Ring 1. End Gap 1. Replace with new piston ring if wear of the NOTE: Measurement of the end gap: cylinder liner is within the repair limit. when no ring gauge is available,

measure the lower part of the cylinder bore. a) Top a) Top: 0.15·0.35mm (0.006·0.014in) a) Top: 0.5mm (0.020in) or more b) Second b) Second: 0.30·0.50mm (0.012·0.020in) b) Second: 07mm (0.028in) or more c) Oil c) Oil: 0.20-0.7mm (0.008-0.02Bin) c) Oil Ring: to be replaced with a new

oil ring, when replacing with new top and/or second rings. Sandpaper means water proof paper.

Piston Pin 1. Outer diameter 1. 16.00mm (0.6299in) 1. 15.97mm (0.629in) or less. Crankshaft 1.Deflection of the crankshaft. 1. Less than 0.05mm (0.002in)-both ends. 1. 0.05mm (0.002in) or more.

Both the main bearings of the crankshaft should be supported with V-blocks.

2. Outer diameter of the crankpin. 2. 29.98mm (1.1803in) it 29.95mm (1.179in) or less. 3. Outer diameter of the bearing. : 3. 31 ;99mm,(1.2594in)- 3. 31.97mm (1.259in) or less. 4. Oil clearance of the bearing. 4. 0.012 • 0.044mm (0.0005 • 0.0017ln) 4. 0.06mm (0.002in) or more. 5. Side clearance of the crankshaft. 5. 0.1 • 0.2mm (0.004 - 0.008in) 5. 0.6mm (0.024in) or more.


12

SERVICE STANDARDS/REPAIR LIMITS/MAINTENANCE Part Name Check/l~ct Standard Value/Maintenance Rl!P_air Limit

Connecting Rod 1. Inner diameter of the small end. 1. 16.01mm (0.630in) 1. 16.04mm (0.631in) or more. 2. Oil clearance of the big end. 2. 0.015 - 0.041mm (0.0006- 0.0016in) 2. 0.060mm (0.002in) or more. 3. Side clearance of the big end. 3. 0.1 - 0.25mm (0.004 - 0.01 in) 3. 0.6mm (0.024in) or more.

Magneto • lnition timing BTDC 5° - 5° (electric ignition advance) • Spark performance 10mm (0.4in) or more/500 rpm

(measured by genuine spark tester. •Spark plug NGK DCPR6E •Spark gap 0.8 - 0.9mm (0.032 - 0.035in) 1.2mm 9 0.0047in) or more • Alternator output 12V, 130W (5000 rpm) •Resistance of coifs Between white wire and yellow wire 0.27- 0.41n Between red-white wire and black wire 148 - 22211 Between black-red wire and blue wire 12.5 -18.8!l Between yellow-red wire and yellow -red wire 1.40 - 2.100 • ESG for high speed Restricting at 6250 rpm • ESG for low speed Reducing at 2000rpm

Ignition Coil • Resistance of primary coll between black wire and orange wire 0.26-0.35.n • Resistance of secondary coil between high tension cord and core 6800 - 10200.n

Battery Output 12V - 70AHto 12V • 100AH 12V0.6KW

Clutch Over-running clutch 1) Brush length 1) 12.5mm (0.49in) 1) 9.5mm (0.37in) or less 2) Commutator under-cut 2) 0.5-0.8mm (0.02-0.03in) 2) 0.2mm (0.008in) or less 3) Commutator diameter 3) 30mm (1.18in) 3) 29 mm (1.14in) or less

Fuse Capacity 120A Thermostat Operation of thermostat e Start to open: 60°C ± 1.5°C If the valve opens at room temperature,

(140 ± 3°F) replace the thermostat. • Temperature at which valve opens While immersing the thermostat in water,

full: 75°C (167°F) raise the water temperature and check the temperature at which the valve opens.

Pump Impeller Worn-out, crack Replace Pump Case Liner Worn-out Replace Guide Plate Worn-out Replace

Intake Valve 1) Valve Clearance IN: 0.13 - 0.17mm (0.005 - 0.007in) Exhaust Valve EX: 0.18 - 0.22mm (0.007 • 0.008in)

2) Outer diameter of valve stem IN: 0.13 - 0.17mm (0.005 - 0.007in) 5.46mm (0.215in) or less EX: 0.18 - 0.22mm (0.007 - 0.008in) 5.44mm (0.214in) or less

3) Inner diameter of valve guide IN: 0.13 - 0.17mm (0.005 - 0.007in) 5.55mm (0.218in) or more EX: 0.18 - 0.22mm (0.007 - 0.008in) 5.57mm (0.219in) or more

4) Clearance to valve stem IN: 0.13 • 0.17mm (0.005 - 0.007in) 0.07mm (0.0028in) or more EX: 0.18 - 0.22mm (0.007 - 0.008in) 0.10mm (0.004in) or more

5) Contact width of valve seat IN: 0.13- 0.17mm (0.005 • 0.007in) 2.0mm (0.079in) or more EX: 0.18 - 0.22mr,n (0.007 - 0.008in) 2.0mm (0.079in) or more

Valve Spring Free length 35mm (1.38in) 33.5mm (1.319in) or less

Camshaft 1) Height of cam (both IN and EX) 1) 23.90mm (0.94in) 1) 23.75mm (0.935in) or less 2) Outer diameter of bearing 2) Pulley side: 17.98mm (0.0708in) 2) 17.95mm (0.707in) or less

Oil pump side:: 15.97mm(0.629in) 15.95mm (0.628in) or less 3) Clearance of holder (bearing) 3) 0.02 - 0.05mm (0.0008 - 0.0020in) 3) 0.09mm (0.0035in) or more

Rocker Arm 1) Inner diameter 1) 13.01mm (0.512in) 1) 13.05mm (0.514in) or less and Shaft 2) Outer diameter 2) 12.99mm (0.511in) 2) 12.94mm (0.509in) or less

3) Shaft Clearance 3) 0.006 - 0.035mm (0.00024 -0.00138in) 3) 0.6 mm (0.0024in) or less Timing Belt Tension and appearance Wear, crack or lengthen-replace

13

SERVICE STANDARDS/REPAIR LIMITS/MAINTENANCE Part Nam e Check/Inspect Standard Value/Maintenance Repair Limit --

Engine Bio ck With de-compressor 0.4 ± 0.1 MPa (5 ± 1 kg/cm'. 71 psi) Pay heed to pressure leak in compression from the rotation, sliding and sealing parts.

Without de-compressor 0.93 ± 0.1 MPa (9.5±1 kg/cm', 135 psi) (rocker arm in EX side is removed)

Carbureto r • Setting mark 3H8A • ThrottleNenturi bore 23/11.5mm

• Main jet (MJ) #68

• Main air jet (MAJ) #135

• Inner diameter of main nozzle 2.2mm

• Slow jet (SJ) #42

• Slow air jet (SAJ) #115

• Opening angle of throttle (at W.0.T.) 80° • Pilot screw (PS) - Blind 1-3/4

• Fuel level (from flange surface 14mm (0.55in) to float bottom

• Resistance of PTC* heater for 20fl auto-bystarter at 20° C (68° F)

(*PTC: positive temperature coefficient thermistor) • Idle speed (clutch in) 900 rpm

Oil Pump 1) Inner diameter of pump body 1) 29.04mm (1.143in) or more 2) Clearance between outer rotor 2) 0.36mm (0.014in) or more

and body 3) Height of outer rotor 3) 14.96mm (0.589in) or less 4) Clearance between rotor and 4) 0.11 mm (0.0043in) or more

body side (incl. wear of the pump cover) 5) Clearance between outer rotor 5) 0.16mm (0.006in) or more

and inner rotor

14

190

ENGINE DISASSEMBLY

Bolts, nuts, and washers are indicated by the symbols below. .,, as~ .,, 40Hol&.; I

H820 - Hexagon headed bolt Diameter 8 mm Length 20 mm ·I/> 32 ... if, 35Hole ·

NS - Normal hexagon nut Diameter 8 mm -t/> 15- t/> 20Hole'

LS - Hexagon lock nut Diameter 8 mm W6 - Plain washer Diameter 6 mm

SW6 - Spring washer Diameter 6 mm Thickness : 30 or more Screw 620 - Pan headed screw Diameter 6 mm Length 20 mm Unit : mm Setting board for power unit

Removing Parts

Oil strainer

<D Cut the hose band and then remove the oil

strainer with the hose from the nipple.

Ignition coil

<D Remove the plug cap from the spark plug.

® Remove the ignition coil fitting bolt

and then remove ignition coil.

C. D. Unit

<D Remove the C.D. unit fitting bolt

then remove the C.D. unit.

· Magneto flywheel cup

<D Remove the flywheel cup with a special tool

according to the instructions of "How to Use

Special Tools': .

Alternator

<D Remove the alternator fitting screw

and then remove the alternator.

Pulser coil

<D Remove the pulser coil fittlng screw

and then remove the pulser coil.

Startor motor and starter solenoid

<D Remove the starter motor fitting bolt

and then remove the starter motor.

@ Pull the starter solenoid from the electric

bracket.

Rectifier

<D Remove the rectifier fitting bolt

Carburetor

Q) Remove the carburetor fitting bolt

and then remo'{e the carburetor together with

the air silencer, insulator and gaskets.

'Fuel pump

Q) Remove the fuel pump fitting bolt

then remove the fuel pump.


15

ENGINE DISASSEMBLY

POWER UNIT Cylinder head, valves and relating parts

NO Part name

Gasket & 0-ring

1 Cylinder head

Intake valve 2

Exhaust valve

3 Valve stem seal - IN Valve stem seal - EX

4 Valve spring

5 Rocker arm

6 Rocker arm shaft

Check point, etc.

Note: Must be replaced by new parts whenever they are once removed for'disassembling.

e Carbon deposit in combustion chamber •Surface width-and roughness between valve seat anct valve e Scratch or distortion

esurface width and roughness between valve seat and intake/exhaust valve

ecarbon deposit

Black color: Wear of contact surface with valve stem Green color: Wear of contact surface with valve stem

eweekness

ewear of three contact points: contact surface with cam, rocker arm shaft and rocker arm washer.

e Wear of contact surface with rocker arm

3. Valve stem seal-EX (Green color)

6. Rocker arm shaft-EX

Cover, Cylinder head

Engines.& Generators

16

VIEW FROM UNDER BASE FRAME

ENGINE DISASSEMBLY POWER UNIT Crank shaft, pistons, cylinder/crank case and related parts

NO. Part name

1 Crankshaft

2 Connecting rod

3 Connecting rod cap

4 Connecting rod bolt

5 Piston

6 Piston pin clip

IQllIDJ Loctite "518"

~ 4-stroke Engine Oil

3. Connecting rod cap

H850·4

123-25 N- ml H630-6

IB-10 N - ml

Check point, etc.

e Oil clearance at main bearings e Oil clearance at big end of connecting rod Note: Align the tab of the metal bearing with the notch in the

cylinder/crank case Note: There are two type of metal bearings

(Thickness code: Black color and Brown color)

Note: Pay attention to the connecting rod orientation for reassembling ("UP" mark must face the magneto side)

Note: Mate the markings of the cap and connectin~ rod with each other ("UP" mark must face the magnetq side)

Note: Tighten the bolts in 'careful manner; 11 Gradually tighten the two bolts alternately seV;eral times so thatthey are evenly tightened.

Note: Pay attention to the piston direction ("UP" mark faces the magneto side)

Note: Don't use the clip that is once removed. Be sure to use a new part for reassembling.

4~ Connecting rod bolt 111-13 N - ml

Oil pressure sw,...,

~1 ~

w WESTERBEKE Engines & Generators

17

5. Piston a,._ 6. Piston pin, Clip

2. Connecting rod

Oil strainer

BEARINGS

ENGINE DISASSEMBLY

ENGINE DRIVE, PULLEY

SHEAVE ARRANGEMENT VIEW FROM UNDER BASE FRAME


18

ENGINE DISASSEMBLY

POWER UNIT Cam shaft, oil pump and related parts

NO. Part name

1 Cam shaft

2 Timing belt

3 Drive pulley

4 Driven pulley

5 Oil pump

HEAT EXCHANGER ASSEMBLY

Check point,' etc.

e Smooth movement of decompressor weight Note: This part is very weak_againstimpact.

Note: Be sure to keep clean free from oil and grease

Note: Be sure to keep clean free from oil and grease Note: Pay attention of direction

("UP" mark faces the magneto side)

Note: Be sure to keep clean free from oil and grease Note: Pay attention of direction

("UP" mark faces the magneto side)

Ii:@!> 4-stroke Engine 011

2. Timing belt

26mmNut ~

134-36 N - m I~

Lock washer ~ Plate~ Mar~

3. Driven pulley ~

Plate_.

HEAT EXCHANGER (FRESH WATER COOLED MODELS) I Decompressor weight ---~R.!1-

The heat exchanger should be removed, inspected, and cleaned. Install a new zinc and fresh hoses with riew clamps at reassembly. If suspect, a local automotive radiator shop should be able to clean and pressure test the heat exchanger. Pin

4. Driven pulley

The water injected exhaust elbow should be removed and inspected for defects and corrosion. Also inspect the siphon break hose and its connections.

Flush out the coolant recovery tank and its connecting hose.

0-ring -d::'.)-~ ©

Loosen the raw water pump, remove the drive belt and then remove the raw water pump.

Remove the engines coolant pump. For servicing, refer to COOLANT PUMP.

Remove the thermostat assembly and clean the interior chambers. Inspect the seals in the pressure cap when reassembling. Replace the thermostat and gasket.

~ ~

5. Oil pump

19

INSPECTION AND MEASUREMENTS POWER UNIT

Measurement with vernier calipers

e Valve seat width

Standard value Out of the limit to use

1.0 mm If 2.0 mm (0.079 in) or

0.0393 in more, it needs replacement or repair.

e Valve spring free length·


35mm · If 33.5 mm (1.319 in) or 1.38 in less, it needs replacement.

Measurement with micrometer

e Outer diameter of piston skirt


58.960 mm If 58.90 mm (2.3189 in) or 2.3213 in less, it needs replacement,

· e Piston clearance (Clearance between piston and cylinder)


0.020 - 0.055 mm If 0.15 mm (0.0059 in) or 0.0008 - 0.0022 in more, it needs replacement.

• Outer diameter of piston pin


16.00mm If 15.97·mm (0.629 in) or 0.6299 in less, it needs replacement.

e Outer diameter of crank pin

Standard value Out of the limit to u~e

29.98mm If 29.95 mm (1.179 in) or 1.1803 in - less, it needs replacement.

e Outer diameter of crank shaft in metal bearing


31.99 mm If 31.97 mm. (1.259 in) or 1.2594 in less, it needs replacement.


20

INSPECTION AND MEASUREMENTS e Cam shaft

Standard Out of the limit value to use

Outer dia. in 17.98.mm If 17.95 mm (0.707 bearing

0.708 in in) or less, it needs

(Upper) replacement.

Outer dia~ ih 15.97mm If 15.95 mm (0.628 bearing

0.629in in) or less, it needs

(Lower) replacement.

Cam height 23.90mm If 23.75 mm (0.935 in) or less, it needs IN&EX o.94in replacement.

e Valve stem

Standard Out of the limit value to use

5.48 mm If 5.46 mm (0.215 IN

0.216 in in) or less, it needs replacement.

5.46mm If 5.44 mm (0.214 EX

0.215 in in) or IEtsS, it needs replacement.

e Clearance between valve guide and valve stem

Standard value Out of the limit

to use

0.008 - 0.04 mm If 0.07 mm (0.0028

IN in) or more, it needs 0.003 - 0.0016 in replacement.

0.025 - 0.057 mm If 0.10 mm (0.004

EX in) or more, it needs 0.001 O - 0.0022 in replacement.

e Outer diameter of rocker arm shaft


12.99 mm If 12.94 mm (0.509 in) or 0.511 in less, it needs replacement.

Measurement with cylinder gauge

e Inner diameter of cylinder

Standard value Out of fhe limit to use

, 59.00mm If 59.06 mm (2.3252 in) or 2.3228 in more, it needs replacement.

e Diameter of piston pin hole


16.002 mm Depends on clearance 0.630 in between pin and hole.

e Clearance between piston pin and piston pin hole


0.002 - 0.012 mm If 0.04 mm (0.0016 in) or 0.00008 - o:ooos in more, it needs replacement.


21

INSPECTION AND MEASUREMENTS

e Oil clearance at big end of connecting. rod m Standard value Out of the limit to use

0.015 - 0;041 mm If 0.060 mm (0.002 in) or 0.0006 - 0.0016 in more, it needs replacement.

• Inner diameter of small end of connecting rod


16.01 mm If 16.04 mm (0.631 in) or 0.630in more, it needs replacement.

• Inner diameter of rocker arm


13.01 mm If 13.05 mm (0.514 in) or 0.512 in more, it needs replacement.

• Oil clearance between rocker arm and shaft


0.006 mm - 0.035 mm If 0.06 mm (0.0024 in) or

0.00024 - 0.00138 in more, it needs replacement.

• Inner diameter (bearing) of cam shaft holder

Standard value

Upper 18.01-18.025 mm (Cylinder head) 0.709 - 0.710 in

Lower (Oil pump)

· • Oil clearance between cam shaft and holder

Standard value · Out of the limit to use

Upper 0.02 - 0.05 mm 0.09 mm (0.0035 in) 0.0008 - 0.0020 in or rqore

Loi,ver 0.02 - 0.05 mm 0.09 mm (0.0035 in) 0.0008 - 0.0020 in or more

If the oil clearance is out of the limit, replace cylinder head and/or cam shaft and/or oil pump.

e Inner diameter of valve guide


5.51 mm If 5.55 mm (0.218 in) IN

0.217 in or more, it needs replacement.

5.51 mm If 5.57 mm (0.219 in) EX or more, it needs

0.217 in replacement.

EX

IN

Engines_ & Generators

22 .


Measurement with thickness gauge

• Clearance between piston ring and ring groove


Top 0.04 - 0.08 mm If 0.1 o mm (O.Q04 in} or 0.0016 - 0.0031 in more, it needs replacement.

Second 0.03 - 0.07 mm If 0.09 mm (0.0035 in} or 0.0012 - 0.0028 in more, it needs replacement.

Oil 0.01 - 0.18 mm If 0.21 mm (0.0083 in) or 0.0004 - 0.0071 in more, it needs replacement.

• Piston ring end gap


Top 0.15 - 0:35 mm If 0.5 mm (0.020 in) or 0.006 - 0.014 in more, it needs replacement.

r--Second

0.30 - 0.50 mm If 0.7 mm (0.028 in} or 0.012 - 0.020 in more, it needs replacement.

Oil 0.20 - 0.70 mm 0.008 - 0.028 in

Note: • Set the piston ring by pressing it in the piston

crown side. ·To be replaced with a new oil ring when replacing

with new top and/or second rings.

• Side clearance at big end of connecting rod


0.1 - 0.25 mm If 0.6 mm (0.024 in) or more, 0.004 - 0.01 in it needs replacement.

• Side clearance of crankshaft

Standard value

0.1 - 0.3 mm 0.004 - 0.012 in

Out of the limit to use

0.6 mm (0.024 in) more

If the side clearance is out of the limit, measure length of the crankcase (cylinder side) and the crankshaft and replace crankshaft and/or cylinder-crankcase ass'y.

Standard value

Crankshaft length 126.8 - 126.9 mm 4.992 - 4.996 in

Crankcase length 127.0 - 127.1 mm 5.000 - 5.004 in


23


5) Measurement with Plastigage® e Oil clearance between crankshaft and metal

bearing 1) Wipe oil out of:

• Crankshaft bearing journals •Metal bearings (both sides) • Bearing· portions of cylinder and crankcase

2) Install metal bearings into the cylinder and crankcase.

Note: Align the tab of the bearing with the notch @ in the cylinder and crankcase.

3) Install the crankshaft to cylinder. 4) Place a piepe· of the plastigage on the

crankshaft main bearing journal. 5) Assenble the crankcase.

Tighten· the crankcase bolts to the specified torque in the i_11dicated order. Torque: : 23-25 N - m (2.3-2.5 kg - m)

(17-18 lb - ft) : :8-1 O N - m (0.8-1.0 kg - m)

. (5.8-7.2 lb - ft)

I Note: Do not crank up the crankshaft.

6) Disassemble the crankcase.

I

7) Measure the compressed plastigage width at its widest point.,

24


0.012 - 0.044 mm 0.06 mm (0.002 in) or less o.ooos - 0.0011 in ~

If the oil clearance is out of the limit, measure inside diameter of the cylinder/crankcase bearing holders and the crankshaft bearing journals. There are within the standard value, replace metal bearings.

e Cylinder/Crankcase bearing holder inside diameter code The codes (2 sort) are stamped on the upper side of the crankcase.

1.0. code Standard value Appling metal bearing

A,X 35.000 - 35.008 mm

Brown color paint 1.3780 - 1.3783·1n

B,Y 35.008 - 35.016 mm

Black color paint 1.3783 ::.... 1 .3786 in

Remark: 1.0. code A and B - For upper bearing holder

1.0. code X and X - For lower bearing holder

INSPECTION AND MEASUREMENTS e Metel bearing thickness code

The codes are painted on the side of the bearing.

Color code Thickness

Brown 1.488 - 1.494 mm 0.0586 - 0.0588 in

Black 1.494- - 1.500 mm 0.0588 - 0.0590 in

e Oil clearance at big end of connecting rod

1) Wipe oil out of the crank pin and big end

bearing of connecting rod.

2) Set the Plastigage to the crank pin and fit it to

the connecting rod. Tighten the bolt with the

specified torque. Plastigage

mm

Tightening torque: 11-13 N-m (1.1-1.3 kg-m) ,

(8.0-9.4 lb - ft)

Note: Do not tum the connecting rod.

3) Remove the connecting rod and check the

Plastigage reading.


0.015- 0.041 m.m If 0.06 mm (0.002 in) or 0.0006 - 0.0016 in less, it needs replacement

e Repair of valve seat 1) Plane the valve seat face with the 45 ° valve

seat cutter.

2) Depending on the situation (the contact position of the seat is too high or too low), use

the 30 ° cutter or 60 ° cutter and then repair the surface area with the 45 ° cutter.

3) Apply Prussian Blue compound (or equivalent) evenly on the seat face. While turning the valve with the valve lapper, check face, wiclth between the valve and valve seat. If necessary, repair.the face width with the V?lve seat cutter.


25


Face width

Standard value Limit that needs repair

IN 1.0mm 2.0 mm or more 0.04in 0.08in

EX 1.0mm 2.0 rilm or more 0.04in 0.08in

: 4) After repair of the valve seat, lap the valve for

good fitting. Apply lapping compound thinly on the seat 11nd lap the valve while turning and tapping it with.

the valve lapper. · Remarks: Since the lapping compound is supplied

in a set of three grades (coarse, medium and fine). lap the valve with all of them in order from coarse, medium

and fine.

Notes:

• When using lapping compound of a different

. grade, completely wipe oU! the previously used

compound beforehand.

e After lapping is complete, wash ~he valve and

valve seat·atter completely wiping the

compound out of them.


26

ASSEMBLY POWER UNIT

Reassembling Engine

Reassemble the engine in the reverse order of

disassembling with careful attention to the

following points.

(1) Cylinder head and related parts

e Valve stem seal

•There are two kinds of valve stem seals, namely,

the valve stem seal for the intake valve is

identified by the black color while the other for

the exhaust valve is identified by the green color.

• On installing the valve stem seal to the cylinder

head, apply the engine oil for the 4-stroke cycle

engine to the insertion point. For setting the

valve stem seal, press it into the valve guide with

fingers.

e Intake valve, Exhaust valve

• The intake valve and exhaust valve are different

from each other, namely the intake valve is

identified by the "IN" mark while the exhaust

valve is identified by the "EX" mark.

• Apply the engine oil for the 4-stroke cycle engine

to the valve stem. Then, insert the valve into the

valve guide while twisting it.

• After setting the cotter on-to the valve stem, tap

the valve shaft end with a small plastic hammer

several times for stabilizing the cotter in setting.

• After reassembling the valves, apply the engine

oil for the 4-stroke cycle engine to the upper side

of the retainer and its periphery.

e Camshaft

• Carefully press the oil pump pin so that it does

not come out of the cam shaft.

• When reassembling the cam shaft to the cylinder

head, apply the engine oil for the 4-stroke cycle

engine to the cam and bearing beforehand and

then insert the cam shaft into the cylinder head

from the oil pump side while twisting it with care

not to turn over the oil seal lip:

e Rocker arm

•Temporarily set the tappet adjusting screw and

tappet adjusting nut to the rocker arm.

Note: Set the tappet adjusting nut with the chamfered · side down.


to the rocker arm shaft.

• Set the rocker arm shaft from the side of the oil

pump of the cylinder head. Pay heed to

orientation of the rocker arm shaft so that the

tapped hole side is positioned in the oil pump

side.

•Set the rocker arm shaft spring, washer, rocker

arm, rocker arm shaft collar to the rocker arm

shaft from the bottom side in this order.

• When setting the above-mentioned parts, apply

the engine oil to every part.

Washer 6.5-19-3.2

Washer

Bolt M6-19

Washer 14.2-25-2.5

Washer 13.2·21.8-2.0

Washer

Rocker arm shaft collar

Rocker arm shalt spring

t Rocker arm shaft setting direction Engines & Generators

27

ASSEMBLY e Oil pump

• Pour the engine oil of approximately 2.0 ml into

the oil pump through the inlet a'nd outlet ports.


to the 0-rings (1.5-10.70, 1.5-8.50, 1.5-15,50)

and the 0-ring at the boss before setting them in

the oil pump.

• When assembling the oil pump to the cylinder

head, carefully set it so that the cam shaft pin

and the notch on the oil pump shaft meet each

other.

• Fasten the oil pump with the three M6 bolts with

the tightening torque and in the tightening order

specified below.

Tightening order: CD. ® and @

Tightening torque: 5-6 N - m (0.5-0.6 kg - m)

on rour J

Oil flNJ

Pin

1 -Cam shaft

--Oil pump

e Plunger

• When setting the plunger stopper into the

plunger case, pay attention to the orientation of

the plunger stopper so that it is set as shown.

• When assembling the plunger assembly to the

cylinder, fasten it together with the cover.


(12-15 lb - ft)

Plunger case

Cover

e Piston ring

Fitting oil rings to piston

1. Set the spacer expander in the oil ring groove,

and check to see if both the ends of it correctly

link with each other as shown in CD.

Oil ri~~liiS

CORRECT

INCORRECT


28

ASSEMBLY 2. While holding down the slit of the spacer

expander with a thumb, set the upper rail as its

slit is deviated from the slit of the spacer

expander at an angle of 90° in the

counterclockwise direction. ® 3. In the same manner as the preceding step, set

the lower rail as its slit is deviated from the slit of

the spacer expander at an angle of 90° in the

clockwise direction. @

Top ring ~ Chrome

~plating Second ring ~

\if..fil1\ Tapered

Check of correct setting of each piston ring

1. Check to see if the slit of each piston ring is not

set in the piston thrust direction or piston pin

direction.

2. After the assembling work is complete, make sure

that each piston ring is set as shown once again.

e Piston and Connecting rod

• Assemble the connecting rod and connecting

rod cap to each other as they were put together

before removing. (Before removing the

connecting rod cap, be sure to leave a markin.g

at a mated point between the connecting rod

and connecting rod cap as a reference for

reassembling.)

._ _________ __, •The upper sides of. the. connecting rod cap,

Fitting compression rings to piston

Fit the compression rings onto the piston in the

correct order to start with the lower ring. Set each

compression ring. with the side marked with the

brand and size up.

Oversize mark

29

connecting rod and piston are identified by the

"UP" mark.

• For inserting the piston and connecting rod

assembly intq the cylinder, use the piston slider.

Apply the engine oil for the 4-stroke cycle engine

to the cylinder liner, piston rings before inserting

the assembled piston.

ASSEMBLY e Cylinder and Crank case

• When fitting the metal bearing to the cylinder

and crank case, set the tab in the notch.


to the metal bearing.

• Degrease the mating surface between the

cylinder and crank case.

•Apply the Locktight #518 to either of the cylinder

and crank case with careful attention to the

applying part and width so as to avoid overflow.

CarefUHy avoid overflow.

Apply Locktight #518 to the black part. Applying width: 1 mm

Matingmark#2

e Fitting cylinder head to cylinder

•Before fitting the cylinder head to the cylinder,

set the piston at the top dead center.

• When fastening the cylinder head, carefully

tighten the bolts with the specified tightening

torque and in the correct order.

5 6

1 2

4 3

Tightening torque:

MB bolt: 28-30 N - m (2.8-3.0 kg' - m)

(20-22·1b - ft)

M6 bolt: 8-10 N - m (0.8-1.0 kg - m)

(5.8-7.2 lb - ft)

• Cylinder head cover

• Fit the gasket to the cylinder head cover and

apply the Three Bond #12078 to the shaded

part shown.

Apply the sealant to the shaded part. Shaded part (Part shown by slanted lines)


(5.8-7.2 lb - ft)


30

ASSEMBLY e Fuel pump

• Make sure that the marks "2" and ~o" on the

driven pulley and the mark " \J " on the cylinder

head are aligned in a straight line.


to the top of the plunger and 0-ring of the fuel

pump. Crank shaft holder

Tightening torque: 5-6 N - m (0.5-0.6 kg - m)

(3.6-4.3 lb - ft)

e Drive pulley

• For tightening the nut to. fasten the drive pulley,

use the crank shaft holder.


(25-26 lb - ft)

Crank shaft

lock washer (Bend it by a part.)

• After tightening the nut, bencf up the lock washer

by a part.

e Oil filter


to the rubber seal of the oil filter.

FILTER WRENCH

Oil FILTER

Tightening torque: 18 N - m (1.8 kg - m)

(13 lb - ft)

• Water Injected Exhaust Elbow

SIPHON BREAK

•Oil Pan Coat the new gasket with three bond #12078 on both sides and mount the oil pan. Tighten the cap screws gradually in opposing order. Torque at 28 - 30 Nm (20 - 22 lb-ft)


31

LUBRICATION SYSTEM

OIL PUMP Using a micrometor, cylinder gauge, depth gauge and feeler gauge, measure the following oil pump clearances. Replace if worn or out of specification.

CD Inner diameter of pump body 29.04 mm (1.143 in) or more

@ Clearance between outer rotor and body 0.36 mm (0.014 in) or more

@ Heigth of outer rotor 14.96 mm (0.589 in) or less

© Clearance between rotor and body side 0.11 mm (0.0043 in) or more (incl. wear of the pump cover)

® Clearance between outer rotor and inner rotor 0.16 mm (0.006 in) or more

0-Ring ---6--~ @>

®@! © I

Pump body

Outerroror ~ Inner rotor ~

I Shatt4 Pin ~

Gasket~ Oil pump cover ---A ~

l--H635-3

@

OIL INSPECTION Always observe the old oil as it is removed. A yellow/gray emulsion indicates the presence of water in the oil. Although this condition is rare, it does require prompt attention to prevent serious damage. Call a competent mechanic if water is present in the oil. Water present in the oil can be the result of a fault in the exhaust system attached to the engine and/or a siphoning through the water cooling circuit into the exhaust, filling it up into the engine. Use an oil test kit and send a sample of the engine oil to a qualified oil test lab for analysis.

WIPE THIS SURFACE CLEAN BEFORE INSTALLING FILTER

OIL FILTER


32

OIL FILTER ASSEMBLY

.OIL PRESSURE SWITCH

.OIL FILTER 'WRENCH

FUEL SYSTEM

FUEL PUMP

OISASSEMBL Y

Before disassembly, make a aligning line on the out

side of fuel pump for correctly reassembling.

CD Remove screw, and take off:

• Outer plate

•Gasket

•Valve body

®Turn the piston clockwise or counter clockwise

until you look the pin from the cutaway of the

pump body.

® Pull the pin, and remove from the pump body:

•Piston

•Spring

•Diaphragm

•Spring

ENGINE FUEL FILTER·

'

Pump body

Inspection:

•Crack and damage

LUBRICATE WITH CLEAN FUEL ANO PRESS THE FILTER ON OVER THE. 0-RING

33

Valve body

Inspection: 9/Wear and damage

Diaphragm

REASSEMBLY Reassembly is reverse order of disassembly

Note:

After connecting the diaphragm rod to the piston with pin, align the diaphragm holes (6) to the pump body holes so that the pin wilt not come out through pump body cutaway.

PINION ASSEMBLY

STARTER MOTOR

STARTER MOTOR

eSNAPRING

STARTER MOTOR

DISASSEMBLY

'(+)POSITIVE FROM , BATTERY

Remove the snap ring from the end of the shaft and the pinion assembly can be disassembled from the front of the housing. Remove the long bolts from the motor base and disconnect

-the wiring connection hardware. This will separate the base from the housmg allowing access to the brush holder assembly.

NOTE: This exploded view is to enable the customer to inspect clean and possiblty repair this starter motor, but parts are no longer available for this model motor.


34

CARBURETOR DC REGULATOR

DESCRIPTION The carburetor is a single barrel, side-draft type with a cleanable metal screen air intake filter/spark arrester.

The choke is operated by a 12 VDC solenoid. The choke solenoid is activated when the start switch is depressed and is controlled by the I.C.M.

Air Screen/Flame Arrester The air screen can easily be removed. Clean after the first 50 hours of operation and every 100 hours from then on. Clean the air screen in a water soluble cleaner such as GUNK.

IDLER Ml

FUEL OVE FL CHAMBER

CARBURETOR WITH SPEED ACTUATOR

Fuel Overflow Chamber Excess fuel drains into the fuel overflow chamber but is drawn out again at start-up. This chamber should be kept free of contaminates. Cleaning every 250 operating hours should be sufficient unless there is a fuel problem.

Idler Mixture Jet Adjustment is performed with the generator operating.Screw the jet slowly in until it seats, then back it out 2 to 3 turns. Maximum adjustment is 5 turns.

NOTE: An idle mixture jet adjusted too far off its seat can induce a sooty exhaust discharge at engine start-up and shut-down.

De-Richening Valve The de-richening valve closes off a fuel port that is supplying additional fuel on a cold start after start up. This is a thermal electric device that slowly moves a needle outward when DC power is applied after start up to close this fuel port. To check this valve, remove from the carburetor (cold) and apply DC voltage across its electrical connections. The devise should get hot and the needle will slowly move· outward. the devise will remain hot during engine operation

Carburetor Bowl. Drain A bowl drain slotted plug is located on the lower right comer of the carburetor bowl. This is located just inboard of the actuators ball joint/clevis.,


35

RAW WATER PUMP IMPELLER

DESCRIPTION Coolant (fresh water) cooled generators have dual water pumps while the raw water cooled models use a single water pump. The pumps are essentially the same. The upper pump mounts to the top of the lower pump and has a tang on the shaft that fits into the shaft of the lower pump. Both pumps are driven simultaneously by the engines drive belt.

The following instructions apply to either pump.

PUMP OVERHAUL Disassembly The pump, when removed from the engine will have the hose attachment nipple threaded into the inlet and outlet ports of the pump along with a drive pulley attached to the shaft of the pump. Remove these attachments noting their positions before starting the pump disassembly.

1. Remove the four cover plate screws, cover plate, and sealing 0-ring.

Dual Pumps Remove the cover screws and the cover will separate the upper pump (raw water)from the fresh water (coolant) pump as shown in the Blustration.

Remove the wear plate to expose the impeller. Notice the direction the impeller blades are working in so as to install the replacement impeller with blades working in the same direction.

2. Remove the impeller using a pair of pliers, grasping the hub and pulling it out of the pump with a twisting motion.

3. · Remove the screw and sealing washer that hold the cam in place. Remove the cam and inner wear plate behind it.

4. Remove the brass cirdip A and brass plate found behind the wear plate.

5. Remove the dust pfa,te and circlip B. 6. Support the pump body on an arbor press and with a drift,

carefully press the shaft and bearing assembly out of the pump body out the pulley end.

7. Remove the slinger 0-ring from the shaft.

8. Support the outer bearing and push the shaft out of the bearing.

9. Remove the spacer and circlip C.

to.Support the inner bearing and push the shaft out of the bearing.

11.Remove the two piece ceramic shaft water seal.

Inspection Inspect all pa.its and replace those showing wear and corrosion.

36

INSPECTION: CHECK AT THE BASE OF EACH BLADE BY BENDING VIGOROUSLY. REPLACE THE IMPELLER IF THERE

~ .AREANYCRACKS.

\________/ °' COVER

a

INSPECT THE 0-RING AND IMPELLER. REPLACE IF ANY SIGNS OF WEAR OR TEARING

LIGHTLY GREASE THE PUMP CHAMBER WITH GLYCERIN

$ CIRCLIP

B

DUST PLATE

IMRELLER PIN FITS INTO SHAFT

SHAFT

SLINGER 0-RING

INNER BEARING

SPACER

OUTER BEARING

0 CIRCLIP c

PULLEY

. RAW WATER PUMP Reassembly Wipe the inside surface of the pump dry. Apply a film of · glycerin supplied in the impeller kit to the inside pump surfaces and to the exposed area of the shaft lip seal.

1. Install a new shaft seal in the pump body. Apply some glycerin to the lip of the seal.

2. Install the circlip shaft. Support the outer bearing and push the shaft into the bearing until the bearing contacts the circlip.

3. Install the spacer against the circlip. Support the inner bearing and push the shaft into the bearing until it contacts the spacer.

4. Warming the pump body should aid in installing the shaft and bearing assembly. Support the pump body on an arbor press. With a twisting motion, install the shaft and bearing assembly into the pump until the inner bearing seats and the outer bearing should just clear the boss for circlip B. Rotate the shaft. It should tum freely.

5. Install circlip B and push the shaft assembly until the outer bearing just contacts circlip B and install the dust plate. Rotate the shaft. It should tum freely.

6. Put some glycerin on the outer surface of the ceramic seal seat and slide it over the shaft white ceramic facing out and seat it in the body of the pump. Place some glycerin on the inner area and with a twisting motion slide it over the shaft until the ceramic of the spring seal touches the white ceramic face.

7. Install the brass plate and circlip A.

8. Install the wear plate, locking it in position on the dowel pin.

Dual Pumps The wear plate is assembled above the impeller.

9. Install the cam and place some gasket cement on the threads of the screw that secures it in place.

10.Place some glycerin on the inner surface of the pump, the inner surface of the cover and the cover sealing 0-ring and with a twisting motion install the impeller on the shaft of the pump. Install the covers 0-ring and cover and secure the cover with the four cover screws.

NOTE: Install the new impellers with a rotating motion so the blades are working in the same direction of those of the removed impeller.

DuaJ.Pumps Assemble the upper pump to the lower pump as illustrated making sure the mounting screws are tight.

UPPER. PUMP SHAFT

THE TANG 01' THE END OF THE UPPER SHAFT FITS INTO THE SLOT IN THE LOWER SHAFT.

PULLEY


37

SCREWS @ FASTENS THE · ~ UPPERPUMP

BODY TO THE LOWER PUMP

THE O·RING!GASKET . ONLY NEE/JS TO BE REPLACES IF IT SHOWS SIGNS OF AGING.

DUAL PUMPS ASSEMBLY

ENGINE TUNING TEST RUN AND INSPECTION AFTER COMPLETE ASSEMBLY

After reassembly, the engine must be tuned. This will ensure that the engine operates at its maximum efficiency.

•Mount the engine on a test bench. • Connect the electrical wiring. refer to the WIRING

DIAGRAM.

e Connect the air intake line to the air cleaner.

• Connect the exhaust. • Fill the engine cooling system with coolant and the engine

oil sump with lube oil.

• Connect the fuel lines. • Crank the engine with the starter (non-ignition operation)

for about twenty seconds. This will pre-lubricate the engine internal components.

• Start the engine and allow it to run five minutes. • Remove the cylinder head cover while the engine is

running.

• Check that the engine oil is continuously circulating from the oil pump to the valve rockers through the cylinder head. If there is no oil circulation or if the oil circulation is sluggish, stop the engine and make the appropriate repairs and adjustments.

• Re-install the cylinder head cover. • Check the engine for oil, fuel, coolant, and air intake

leakage.

• Check for abnormal noise and odor. • Check for abnormal electrical charging. • Check the engine fastening parts for looseness. • Check the operation of the start/stop switch and LED

panel lights. • Adjust the engine speed to the specified value for

generator operation. • Stop the engine to complete the tuning procedure. • Additional tightening after test run. Check the tightening

condition of respective bolts and nuts after test run, and additionally tighten them with the specified tightening torques.


38

ENGINE ADJUSTMENTS ENGINE COMPRESSION TEST To check the engine's compressimi pressure, wann up the engine, then shut it down.

1. Remove both spark plug caps and both spark plugs.

2. Install a compression adapter and gauge in a spark plug hole.

3. Close the thru hull valve (seacock).

WATER PUMP BELT

4. Crank the engine several times quickly so that the gauge ·same. pointer reaches it's maximum.

STANDARD COMPRESSION PRESSURE AT 500 RPM: 71 psi, (5 .1 kgf/CM ) ,(0.50 MPa) with decompressor 186 psi, (13.8 kgf/cm ), (1.35 MPa) without decompressor

5. Test the compression pressure on the other cylinder. If either cylinder is below the standard try adding a small amount of engine oil through the spark plug hole and repeat the test. (a) If additional oil causes an increase of pressure,

the piston ring and/or cylinder may be worn or damaged.

(b) If additional oil does not increase compression pressure suspect poor valve contact, valve seizure or valve wear.

6. Reinstall the two plugs, connect the wires and open the· thru hull valve Cseacock).

IGNITION TIMING The magneto employs the electric ignition advance system that advances ignition timing with an increase of engine speed. While running the engine, check the ignition timing with a timing light. There are nine (9) markings (TDC, ATDC 5° and BTDC 5°, 10°, 15°, 20°, 25°, 30°, 35) on the flywheel cup. Check the timing while observing the position of the carved marking on the starter case.

. ,,, WATER PUMP BRACKET

"lr li'1t'/~ ~/ ==-=----· -----=~ I!

NOTE: The a.dju.s~;ient is the same for the FRESH WATER COOLED MODEL dual pumps.

BTDC IGNITION TIMING IN DEGREES

30

2s-1-~~-+~:::_.~~~

20

10

5

0 i..--.i....~1--.....1---i.-....t.-...1

I r

FLYWHEEL 0 3 4 5 6x103

Engine speed rpm

--CARVED MARKINGS -== /w/WESTERBEKE

I Engines & Generators

39

ENGINE ADJUSTMENTS ADJUSTING THE DRIVE BELT The engine's drive belt is located under the engine. To access the belt, for inspection and/or adjustment, remove the cover as shown. Inspect the belt for wear along the edges and for proper belt tension (belt should be tight).

TI1e belt tension ca11 be checked by meassuring the spring length. 11/4in (31.79mm)

To set the spring tension at 1-1/4", release the jam nut and use a rod such as an alien wrench to turn the adjustinff nut (as shown) to tighten or loosen the spring tension, which in turn adjusts the tension on the belt.

COVER

. IT IS NORMAL FOR SOME BELT DUST TO ACCUMULATE IN THE ENGINE PAN, SIMPLY WIPE CLEAN

BELT ASSEMBLY VIEWED FROM BELOW

* IMPORTANT: REFER TO THE WESTERBEKE SERVICE BULLETIN (LAST PAGE IN THIS MANUAL) FOR THE ADDITION OF A SPACER ON THE 3.0BCG MODEL.

BELT ASSEMBLY VIEWED FROM BENEATH

The lubricating system is a pressure feeding system using an oil pump. The engine oil is drawn from the oil sump by the oil pump, which drives the oil, under pressure, through the oil filter and vmious lubricating parts in the engine. The oil then returns to the oil sump to repeat the continuous cycle. When the oil pressure exceeds the specified pressure, the oil pushes open the relief valve in the oil pump and returns to the oil sump, keeping the oil pressure within it's specified range.

TESTING OIL PRESSURE To test the. oil pressure, remove the oil switch and install a mechanical oil pressure gauge in it's place, it will be necessary to connect the two switch wires together for the engine to nm. After warming up the engine, with tlie engine speed at 2200 rpm, read the oil pressure gauge. OIL PRESSURE: between 30 and 40 psi al 2200 rpm

NOTE: A newly starter (cold) engine may have an oil pressure up to 40 psi. A wanned engine can have an oil pressure as low as 30 psi. Oil pressure will vary depending on the load placed on the generator.

OIL PRESSURE SWITCH/SENSOR The generator is ntted with an oil pressure shutdown switch. Should the engine's oil pressure drop below the safe minimum, the switch will shut the engine down to prevent damage by intetrupting the DC voltage to the ignition coil.

NOTE: The specified minimum oil pressure is 5 psi. A gradual loss of oil pressure usually indicates worn bearings. For additional infomiation on low oil pressure readings, see the ENGINE TROUBLESHOOTING chart.

l "flllY'/WESTERBEKE Enaines & Generators

40

ENGINE ADJUSTMENTS SPARK PLUGS The spark plugs should be cleaned and re-gapped after the first 50 hour break-in period, then inspected every 250 hours thereafter and replaced as needed.

A WARNING: Do not remove the spark plugs while the engine is hot. Allow the engine to cool before removing them.

SPARK PLUG GAP: 0.032- 0.035in. (0.8 • 0.9mm).

SPARK PLUG TORQUE: 11 -15 lb-ft (15- 26 Nm).

NOTE: Loctite Anti-Seize applied to the threaded portion of the spark piugs will retard corrosion, making future removal of the ,\park plugs easier.

t

INSPECT FOR / WEAR & CARBON,,,.-

INSPECTING THE SPARK PLUGS

CHOKE SOLENOID

'--.__CHECK FOR DETERIORATION ANDDAMAGE

The choke solenoid is a 12 volt DC operated unit that is an integral part of the carburetor. When the engine is cold, extra fuel is supplied to the engine. The choke is controlled by the ignition control module and requires no adjustments.

ZINC ANODE [Raw Water Cooled Models} The zinc anode is located just below the thermostat cover and next to the oil filter.The purpose of the zinc anode is to sacrifice itself to electrolysis ai::tion taking place in the raw water cooling circuit, thereby reducing the effects of electrolysis on other components of the system. The condition of the zinc anode should be checked monthly and the anode cleaned or replaced as required. Spare anodes should be carried on board.

NOTE: Refer to the Cooling System pages.for Fresh Water Cooled Thermostat and Zinc Anode assemblies.

THERMOSTAT [Raw Water Cooled Models} A thermostat controls the coolant temperature as the raw water continuously flows through the closed cooling circuit. When the engine is first started, the closed thermostat prevents the water from flowing (some water is by-passed around the thermostat to provide coolant circulation in the engine block). As the engine warms up, the thermostat gradually opens. The thermostat is accessible and can be checked,, cleaned, or replaced easily. Carry a spare thermostat and gasket.

If you suspect a faulty thermostat, place it in a pan of water and bring to a boil. A working thermostat should open when heated and close when cold.

ZINC ANODE

THE GASKET IS SEALED TO THE CASTING AND, UNLESS DAMAGED, CAN BE LEFT IN POSITION. ADD SEALANT TO THE GASKET SURFACE WHEN REASSEMBLING THE COVER.

ZINC ANODE AND GASKET


41

. ENGINE ADJUSTMENTS

INSPECTION/REPLACING OF THE TIMING BELT If cracks, wear, lengthening or other damage is found, replace the ti.ming belt.

LIMIT OF ELONGATION: MORE THAN 10mm (0.4 IN) DEFLECTION BY PUSHING WITH YOUR FINGER

Replacement of the Timing Belt 1. Remove the parts in the following order:

a. Spark Plugs

b. Voltage Regulator

c. Unplug MPU

d. Unplug Cam Sensor

e. Flywheel Housing

f. Flywheel assembly

g. Altemafor Bracket

2. Turn. the crankshaft and align "O" mark on: the drive pulley and the "O,, inark: on the ·cylinder head.

3. · Remove the timing belt from the driven pulley side. 4. Install the timing belt froni the drive pulley side.

NOTE: After insttitllng the timing belt, when the aligning "O" rnark on the drive puUey with "O" on the cylinder block Please confirm that the "l & O" or "2 & 0" mark on the driven pulley are aligned with the ''\!" mark on the cylinder head. · , '

NOTE: Always k2ep the timing belt away from (my oil and grease.

' TIMING BELT.

l...Y.IWESTERBEKE (Engines & Generators

43

FLYWHEEL ASSEMBLY

ALTERNATOR BRACKET I

ELECTRONIC GOVERNOR DESCRIPTION The system is composed if three basic components. 1. Controller. The PC board that governs the system is Iocat~d in the control panel. · · , 2. Sensor. Mounted on the flywheel cover, the sensor measures the speed of the engine (via the ring gear).

3. Actuator~ Electronically controls the carburetor throttle. The sensor and actuator are wired thru the wiring hamess to. the controller (PC board).

.SENSOR

ADJUSTMENT PROCEDURE

, !!,•n (0~762mrn)

INSTALLING THE SENSOR THREAD THE SENSOR IN TO CONTACT THE FLAT ON THt RING GEAR TOOTH. BACK OUT THE SENSOR ONE TURN AND TIGHTEN THE JAM NUT TO SECURE.

tSPEED ACTUATOR

Speed. This adjustment is used to raise or lower the engine's speed. This generator engine is set to run at 2200RPM. Gain. Adjusts the overall set of the engine. If too low, the engine seems sluggish, to high causes the engine to hunt. Stability. Adjusts the engine's response to generator load changes. · Altemator.Feedback.·Adjusts the stability of the speed signal to the throttle actuator. NOTE: These adjustments are extremely delicate and require proper meters for measuring voltage and RPM'S.

ADJUSTING THE CONTROLLER PODS Following are the basic procedures for adjusting the speed (Pl). stability (P2), gain (P3), and actuator feedback (P4) pots.· The adjusting pots (except speed) have physical internal stops. Turn to the right (clockwise) to increase, turn to the left (counter-clockwise) to decrease.

..CONTROL .PANEL (INTERIOR VIEW)

Before starting the engine

~.

CONTROLLER GOVERNOR PC BOARD

GAIN (P3)

-STABILITY (P2)

SPEED {P1)

'{!)r---. ACTUATOR FEEDBACK (P4)

B Remove all loads and turn off the AC circuit breaker to insure that loads will not be subjected to voltage variations while these adjustment are made.

• Decrease the speed pot to prevent overspeed at start up. • Turn the other adjustment pots to the middle position.

Start. the engine, monitor speed. and adjust to the hehz rating of the unit by adjusting the. SPEEO (Pl) as needed. Verify that the AC voltage output is in the correct range. Decreasing the gain (P3) dampens no load hunting. With the

· engine running at no load and proper speed, manually bump the throttle lever to cause hunting. If necessary, decrease the gain in small increments to eliminate hunting .

. After the engine's no load speed and gain are set correctly, . the AC circuit breaker can be ~ed on and the ships load · applied. In the event of speed variations with loads applied, · the stability (P2) pot may need adjustment. This adjustment also changes how the engine responds to generator load changes. If the range of adjustment of eithe:t: gall}. (P3) or stability (P2) pots do not corr.ect engine hunting, the actuator feedback (P4) pot can be increased. This adjustment dampens the signals to the throttle control actuator. Increasing this,. adjustment will decr:ease the amount of throttle ·control resolution. Because of this, it is recommended the adjustment be made in very small increments. The gain and ru.bility pots may now need to be readjusted, Most hunting problems occur because of mechanical problems with the linkage between the actuator and the carburetor. Insure that the linkage is free of any debris or corrosion .and that it moves freely. It is reco:rllo/ended that the linkage be lubricated with a graphite lubricant. Do not use oil because it tends to collect dirt and dust. NQTE: Adjustments to one parameter may affect others, such as speed. It may be necessary to readjust some pots throughout this process.


44

MAG.PICK-UP 950-1000Cl

SKI tLOCD

T3 H

GENERATOR WIRING DIAGRAM RESISTANCE VALUES IN OHMS IN BLACK ITALIC

CARBURETOR SOLENOIO

) 148·222[} PULSER COIL

116 RED/ HT ~ fl II EO/ HT

ti& 8LU

'( __ 12.5 • 18.5 n EXCITER COIL

20/l

IGNITION MODULE

OE-RICHENING VAL vi;

IGNITION COIL

ti& RED/VIO

; ;; ;

VOLTAGE REOIJLA TOR

RESISTANCE VALUES IN OHMS MAGNETO COIL ..................... 1.4 • 2.1

EXCITER CDIL.. ..................... 12.5-18.8

PULSER C.DIL ...................... 148 • 222

ALTERNATOR COIL .................. 0.27 • 0.41

IGNITION COIL ....................... 0.26 • 0.35 (Primary)

MAGNETIC i'ICK-UP ............... 950-1000. START SOLENOID ................... 4.7

HIGH TENSION LEADS .............. 6.8.00·10.000

DE-RICH VALVE-~ .................. 20 ACTUATOR ........................... 3.0 ·3.1

NOTE: TESTER USED· FlUKE MULTIMETER TOLERANCE ± 20%

BATTERY 1i voe

#8 Bl.K

FUSE IOA

REMOTE SHUTOOWk TERM I HAL UNIT CAN I: POSITIVE I+) RESTART 2: AUX. SHUTOOl'/M

UH IT CAM 3: EMERGENCY STOP NOT RESTART 4: GROUND < • l .

JUMPER<SI MUST BE REMOVED

OVERSPEED PC BOARD (PN lt045377) CONTROL PC BOARD (PN # 045369)

TERMINALS 1 & 2 ARE FOR "FIREBOY" CONNECTION

.TERMINALS 3 & 4 ARE FOR "EMERGENCY STOP SWITCH"

II B GRN/REO

COIL REI.AV

EtfG IHE CONNECTOR

CONTROL PC BOARD

tl6 RED/ HT

116 BLK

4116 ORG

PANELi REMOTE CONNECTOR

CONTROL PC BOARD

PART NUMBERS: REMOTE STOP/START PANEL lt048056 PANEL EXTENSION HARNESS 15FT lt048200, 30 FT lt048201

RED ISOLATION POST

WHITE N

AC OUTPUT CONNECTIONS 120V 611Hz

0

45

GREEN TO STARTER GROUND

220V·50HZ

CONNECTIONS FOR 230V50Hz

0 0

0 0

L N LOAD

+

SPARK PLUGS

Oil. PRESS SWITCH

jlWA~T~

EXHAUST TEMPERA l\JRE

SWITCH

.. "

HOUR METER

STARTISTOP SWITCH

3.0 KW GENERATOR SPECIFICATIONS . . .

ENGINE SPECIFICATIONS COOLING SYSTEM Engine Type

Bore & Stroke

Total Displacement

Bearings

Valve System

Compression Ratio

Aring Order

Aspiration

Direction of Rotation

Inclination

Dry Weight.

Governor

Fuel Pump

Fuel

Ignition Timing

Ignition Con

Aame Arrester

Carburetor

Fuel Consumption (Fun Load)

Ignition Timing

Start Motor

Starting Battery

Battery Capacity

Battery Charging .

DC Amperage Draw

Type

Oil Fnter

Oil Capacity

Oil Grade

Two cylinder, four strq~I! gasoline engine.

2.32 x 2.36 inches (59 x 60 mm)

20.01 Cubic Inches (.33 liter)

Two main bearings.

Overhead cam-cross flow.

9:1

1-2

Naturally aspirated.

Counterclockwise viewed from the back end.

25° maximum angle of operation

165 lbs (75 Kg)

Bectronic

FUEL SYSTEM Mechanical fuel pump.

Unleaded 89 Qctane or higher gasoline.

BTDC 25° (not adjustable).

12 volt.

Metal screen type.

Single barrel side draft.

0.4 GPH@ 2200 RPM/25 Amps

12-Volt flywheel magneto.

ELECTRICAL SYSTEM 12-Volt Direct Drive-Remote Solenoid 12-Volt, (-) negative ground

600-900 Cold Cranking Amps (CCA)

11 Amp

70 Amps DC Cranking

LUBRICATION SYSTEM 'Wet sump system trochoid type pump.

Fuel flow, paper element, spin-on disposals.

1.5 qts. (91.4 L)

API Service Calegol'Y SJ, SL, SM, SN or belier SAE 10W-30 or 15W-40

General

Raw Water Pump

Raw Water Row (into water injected exhauSt elbow)

Operating Temperature

Water cooled via raw water pump.

Positiv,e displacement type, rubber impeller, belt driven.

1.75 GPM'(before thermostat opens)

2.0 GPM (thermostat open)

140°F (60°C)

AC GENERATOR (SINGLE PHASE) Type

Speed

3.0Kw

Permanent magnet generator (two pole) Brushless/capacitor (two pole)

3600 RPM/ 60Hz. 3000 RPM / 50 Hz.

3.0 KW - 60 Hz single phase, 120 volts 2 wire, 25 amp.

3.0 KW - 50 Hz single phase, 230 volts 2 wire, 13 amp.

TUNE-UP SPECIFICATIONS Spark Plug Gap

Spark Plug Torque -

Bolt Torque

0.032 - 0.035in (0.8 - 0.9mm)

11-15 lb-ft (15-20 Nm)

See TORQUING THE CYLINDER HEAD.

AIR REQUIREMENTS Engine Combustion

Generator Cooling

13 CFM (0.287 cmm)

200 CFM (5.66 cmm)

FRESH WATER COOLED MODELS Cooling System

Fresh Water (coolant) Pump

Raw Water PulTlp

Raw Water Row (into water injected exhaust elbow)

Operating Temperature

Fresh water cooled block, thermostatically controDed thru a heat exchanger.

Positive displacement, rubber impeller belt driven

Positive displacement, rubber impeller belt driven

2.5-3.0 GPM 9.5-11.3 LPM

180°F (82°C)

Engines & Genera.tors

46 .

AC GENERATOR

PERMANENT MAGNET GENERATOR Engine rpm at 2200 Generator turns at 3600 (60 Hz), 3000 (50Hz) 60Hz 120 volts/25 amps, 50 Hz 230 volts/13 amps

A WARNING: Do not attempt to make adjustments or repairs to the generator. the generator is maintenance free. It the generator tails (no ac output}, contact your WESTERBEKE dealer or distributor.

Required Operating Speed Run the generator first with no load applied, then at half the generators capacity, and finally loaded to its full capacity as indicted on the generators data plate. The output voltage should be checked periodically to ensure proper operation of the generating plant and the appliances it supplies. To monitor voltage and load, check it with a portable meter and ampprobe.

Generator Maintenance Maintaining reasonable cleanliness is important. Connections of terminal boards and rectifiers may become corroded, and insulation surfaces may start conducting if salts, dust, engine exhaust, carbon, etc. are allowed to build up. Clogged ventilation openings may cause excessive heating and reduced life of windings.

In addition to periodic cleaning, the generator should be inspected for tightness of all connections, evidence of overheated terminals and loose or damaged wires.

MOTOR DATA The power required to start an electric motor is considerably more than is required to keep it running after it is started. Some motors require much more current to start them than others. Split-phase (AC) motors require more current to start, under similar circumstances, than other types. They are commonly used on easy-starting loads, such as washing machines, or where loads are applied after the motor is started, such as small power tools. Because they require 5 to 7 times as much current to start as to run, their use should be avoided, whenever possible, if the electric motor is to be driven by a small generator. Capacitor and repulsion-induction motors require from 2 to 4 times as much current to start as to run. The current required to start any motor varies with the load connected to it. An electric motor connected to an air compressor, for example, will require more current than a motor to which no load is connected.

In general, the current required to start 115-Volt motors connected to medium starting loads will be approximately as follows:

MOTOR SIZE AMPS FOR AMPS FOR (HP) RUNNING J!STARTIN~L (AMPERE~ AMPERES 1/6 3.2 6.4 to 22.4* 1/4 4.6 ' 9.2 to 32.2* 1/3 5.2 10.4 to 72.8* 1/2 7.2 14.4 to 29.2* 3/4 10.2 20 .4 to 4@._* 1 13 26 to 52

*NOTE: In the above table the maximum Amps for Starting is more for some small motors than for larger ones. The reason for this is that the hardest starting types (split-phase) are not made in larger sizes.

Because the heavy surge of current needed for starting motors is required for.only an instant, the generator will not be damaged if it can bring the motor up to speed in a few

. seconds. If difficulty is experienced in starting motors, turn off all other electrical loads and, if possible, reduce the load on the electric motor. ·

GENERATOR FAILURE Should a failure occur in the permanent magnet generator, contact your Westerbeke dealer of the Westerbeke factory.

NOTE: It would be important to inspect the pulley and drive belt under the generator base frame.

lwlWESTERBEKE l Engines .&·Generators

47

BCGBACKEND COMPONENTS (TOP VIEW)

.CAPACITOR

THESE COMPONENTS ARE LOCATED ON THE ROTOR .

AC TERMINAL BLOCK ..

. GRCiOND~ . . .

~WINDING RESISTANCE (Measured at 20'C/68'f) 60 Hertz Models : Stator Winding 0.93 Ohm/winding. Rotor Wmding - 4.0 Ohm Excitor Winding - 2.0 Qhm Capacitor Rating - 34 uF

50 Hertz Models : Stator Winding 1.35 Ohm/winding. Rotor Winding• 4.0 Ohm Excitor Winding - 2.S Ohm Capacitor Rating - 31.55 uF

BCG INTERNAL WIRING DIAGRAM ROTOR STATOR

I

I •N.WHITE I .

WHITE

'12ov· 1· . I • THERMISTER .

ILBLA K I .

I , BLACK

I

GREEN YELLOW OR

.·BLUE

I

'

~ :1

i ;I

.11

EXCITOR

·11 RED RED

~~ CAPACITOR

BY-PASSING THE OVERSPEED BOARD An unwanted shutdown or if the engine runs 10-15 seconds and then shuts down can be caused by a faulty over-speed board. 1. Refer to the Wiring Diagram in this manual. 2. Unplug the brown #6 wire that connects between pin #12

of the 15 pin plug connector and the ignition module. The wire plug connection is in the harness between the two components.

3. Without unplugging any connections on the coil relay, place a jumper between connection #30 and #87.

4. Manually controlling #30 and #87, start the engine physically controlling the actuator/throttle keeping the engine speed at a low comfortable range. If the engine continues to run more than 15 seconds, a faulty overspeed board exists.

NOTE: The above should only be performed as a test. The generator with a by-passed overspeed board should not be run under normal use. This can present a ~ard.


48

BCG/BPMGDESCRIPTION. and· TROUBLESHOOTING REFER ALSO TO THE SPECIFICATION PAGE

BRUSHLESS CAPACITOR GENERATOR (BCG) Engine RPM at 2200 generator turns at 3600 (60Hz) 3000 (SOHz) 60Hz 120 Volts/25 Amps SOHz 230 Volts/13 Amps

NOTE: Refer to the following page for the BCG lnte1!'JU1l Wiring Schematic and BCG Winding Resistances.

DIAGRAMS ARE FOR BOTH MODELS

RED ISOLATION POST

WHITE N

120V/60Hz

BLACK

AC CIRCUIT BREAKER

BCG/BPMG AC OUTPUT CONNECTIONS DIAGRAM jj

GREEN TO srARTERJiRDUND RED IS_OLATION POST

WHITE AC~------.

,-.::v-1---B-LA-CK....,..----. ZZOV·50HZ

230V/50Hz

PERMANENT MAGNET IR GENERATOR (BPMG) Engine RPM at 2200 generator turns at 3600 (60Hzj 3000 (50Hz) 60Hz 120 Volts/25 Amps 50Hz 230 Volts/13 Amps

rROUBLESHOOTING CHART (BCG) CAUSE FAULT

No AC Output Voltage 1. Shorted Stator. 2. Open Stator. 3. Shorted Rotor Diode. 4. Shorted Rotor Thermister. 5. Shorted Rotor Gapacitor. 6. Open Rotor Diode.

Residual Voltage 1. Faulty Capacitor. Line - Neutral at 2. Open Exciter Winding. No Load 3. Shorted Exciter Winding.

Low AC Output 1. Faulty Rotor Diode. Voltage 60 -100 Volts 2. Faulty Rotor Winding.

3. Faulty Exaiter Capacitor.

AC Voltage Drop with 1. Faulty Rotor Diode. Inductive Load 2. Faulty Exciter Capacitor.

3. Amperage Overload.

Refer to the following page for the BCG Internal Wiring Schematic and the BCG Winding Resistances.

TROUBLESHOOTING CHART (BPMG) CAUSE FAULT

No AC Output Voltage 1. Shorted Stator Winding. Open Stator Winding.

Low AC Output 1. Faulty Rotor. Voltage 60 - 100 Volts

Voltage Drop 1. Generator Overload. Under Load

WINDING RESISTANCE (Measured at 20°C/68°F) PM (Permanent Magnet) stator winding resistance 0.4 ohm hertz model resistance is measured between line and neutral. 50 hertz models is 0.8 ohm. NOTE: The permanent magnet style generator can not be disassembled. If an electrical fault should occur, the generator must be replaced.

NOTE: It would be important to inspect the pulley and drive belt under the generator base frame.


49

FLUSHING THE COOUNG,SYSTEM

RAW WATER COOLED

RAW WATER PUMP

Engine flushing should be performed a minimum of at least twice per operating season. More often in those areas ~here the unit is not subject to winter storeage. In those locations where the unit is used year round, flushing the unit every 4 months is recommended. This procedure is best accomplished by disco~ecting the water intake hose from the vessels thru-hull fitting. Close the intake valve before disconnecting the hose. Insert the hose end into a large container of fresh water.

Before starting the engine, remove the engine thermostat (replace the gasket and cover). This will ensure a full flow of water thru the engine. Re-install the thermostat once flushing is complete.

NOTE: Prior to flushing the engine/ inspect the coolant bypass hose and its attachment fittings to insure that there are no obstructions occurring in thefittings or the hose. · Provide an external fresh water:s1,1pply for the bucket to maintain the water level in the bucket while the unit is being operated during the flushing process.

REMOVE THERMOSTAT DON'T FORGET TO REPLACE

REPLACE COVER AND GASKET

THERMOSTAT ASSEMBLY

'--~-""~-"-~-----'!.

·---..... -.. ~~'\\ '

EXTERNAL FRESH WATER SUPPLY

A CAUTION:. Oil not connect an external fresh water supply directly to the engine's cooling system. This can cause flooding of the engine resulting in internal damage.

Run the unit for 10 minutes or longer to adequately flush the cooling system.

the fresh water will flush out the engines water passages and exhaust lines. If the engine is being stored and there is a probability of freezing, flush the engine with fresh water and then prior to shutting the unit down substitute the fresh water supply with a concentrated antifreeze mixture and run this through the engine to provide freeze and corrosion protection for both the engine and exhaust system.

When recommissioning, make certain the valves and seacocks are open so the engine will quickly receive fresh water.


50

ENGLISH TO METRIC CONVERSION CHART Mult!Qly Temperature B_y_ To qet ~uivalent number of:

Dimree Fahrenli'eit.J'.'6- .fF-3fl + 1.8 Ofillree Celsius °CJ_

Multfil!y_ Acceleration B_y_ To_g_et ~uivalent number of:

FooVsecond1ft/sec:i.. 0.3048 Meter/second1mts:i..

lnch/second2(1n./seci. 0.0254 Meter/second2 (mis:>_

Mult~Tor.g__ue By To _mlt ~ulvalent number of:

Pound-inch J!b·in_l 0.11298 Newton-meters JN ·mi Pound-foot J!b·f!l 1.3558 Newton-meters JN-ml

Multiply Power ~ To get equivalent number of:

Hors®9Wer J_f:mL 0.746 Kilowatts J!<WJ_

Multm!Y_Pressure or Stress B_y_ To_g_et ~uivalent number of:

Inches of water J!n. H..!2. OJ_ 0.2491 K'rl<?Q_ascals J!<Paj_

Pounds/~uare in. J!b!in.:l_ 6.895 KiloPE!Scals J_kPaj~

Multililir_ Ene!Jllf._ or Work ~ To _g_et ~uivalent number of:

British Thermal UnitJ.!3t!J1. 1055 Joules Jn_

Foot:12_oundJ_ft.Jbl 1.3558 Joules Jn_

ki.lowatt-hour {kW-hr) 3,600,000. or

Joules (J = one W/s) ~~·

Mutt~ L!g_ht ~ To ..9_et ~uivalent number of:

Foot candle Jf9.. 1.0764 Lumens/meter2Jlm/m~

Multipjy_ Fuel Performance lk. To_mlt ~ivalent number of:

Miles{g_al l_milefg_aJl 0.4251 Kilometers/liter j_km/Ll

Gallons/mile JgaVmilfil 2.3527 Liter/kilometer j_Ukl'I})_

Mult.!2!Y. Veloci!Y_ ~ To_get ~ivalent number of:

Miles/hour {mile/hli 1.6093 Kilometers/hour J_krnlhrl..

Multm!Y_ Lel!filh B_y_ To_g_et ~ivalent number of:

lnchJjn_l 25.4 Millimeters l.mn:il.

FootJ_fl;}_ 0.3048 Meters .in:!l Yard~ 0.9144 Meters _{!nJ.

Milej_mifel 1.609 Kilometers Jkm_l

Multm!Y. Area 6Y To__ru!t i:m_uivalent number of:

lncJ:Bjn.21_ 6452 Millimeters~m2l

lnch2{in.2} 6.45 Centimeters:i_ cml)_

Foot:!_ft:l_ . 0.0929 Meters_:Lnfl.

Yard~d::l. 0.8361 Meters:Lm2_l

Mult!J:>Iy_ Volume ~ To_get eauivalent number of:

lnch~n.~ 16387 Millimeters:£_ mm~

lnch~n.~ 16.387 Centimeters~cm~

lnch~in.3} 0.0164 Litersj!J_

Quart jg!)_ 0.9464 Litersj!J_

·Gallon Jg_aJl. 3.785 Litersfil

Yard!lfuj~ 0.7646 Meters3(rn~

Multiply Mass B_y_ To ..9_et ~uivalent number of:

PoundJ!Ql 0.4536 KilQQ!"ams J!sg}_

. - Jon..(!oll). ··--··-· 907.18 Ki].Qgrams J!sg}_

Tonj!oril. 0.907 Tonne..fil_

MultlPk Force lk. To_g_et e..9_uivalent number of:

Kil<mramJ!sgl 9.807 Newtons l_N_l

OunceJ.o~ 0.2780 Newtons lN)_ PoundJ!Ql_ 4.448 Newtons ..llill

~nglnes & Generators

51

STANDARD AND METRIC CONVERSION DATA LENGTH-DISTANCE

Inches .(in} x 25.4 = Millimeters {mm} x .0394 = Inches Feet (ft) x .305 = Meters (m) x 3.281 = Feet Miles x 1.609 =Kilometers (km) x .0621 =Miles

DISTANCE EQUIVALENTS 1 Degree of Latitude= 60 Nm= 111.120 km 1 Minute of Latitude = 1 Nm = 1.852 km

VOLUME Cubic Inches (in3) x 16.387 =Cubic Centimeters x .061 =in3

Imperial Pints (IMP pt) x .568 = Liters (L) x 1.76 = IMP pt Imperial Quarts (IMP qt) ·x 1.137 = Liters (L) x.88 = IMP qt Imperial Gallons (IMP gal) x 4.546 = Liters (L) x .22 = IMP gal lmp~rial Quarts (IMP qt) x 1.201 =US Quarts_ (US qt) x .833 =IMP qt Imperial Gallons (IMP gal) x 1.201 =US Gallons (US gal) x .833 =IMP gal Fluid Ounces x 29.573 = Milliliters x .034 = Ounces US Pints (US pt) x .473 = Liters(L) x 2.113 =Pints US Quarts (US qt) x .946 = Liters (L) x 1.057 = Quarts US Gallons (US gal) x 3.785 = Liters (L) x .264 = Gallons

MASS· WEIGHT Ounces (oz) x 28.35 =Grams (g) x .035 =Ounces Pounds (lb) x .454 =Kilograms (kg) x 2.205 =Pounds

PRESSURE Pounds Per Sq In (psi) x 6.895 = Kil6pascals (kPa) x .145 =psi Inches of Mercury (Hg) x .4912 =psi x 2.036 =Hg Inches of Mercury {Hg) x 3.377 = Kilopascals (kPa) x .2961 = Hg Inches of Water {H20) x .07355 =Inches of Mercury x 13.783 = H20 Inches of Water (H20) x .03613 =psi x 27.684 = H20 Inches of Water (H20) x .248 = Kilopascals (kPa) x 4.026 = H20

TORQUE Pounds-Force Inches (in-lb) x .113 =Newton Meters (Nm) x 8.85 =in-lb Pounds-Force Feet (ft-lb) x t .356 = Newton Meters (Nm) x .738 =·ft-lb

VELOCITY Miles Per Hour (MPH) x 1.609 = Kilometers Per Hour (KPH) x .621 = MPH

POWER Horsepower (Hp) x .745 =Kilowatts (Kw) x 1.34 =MPH

FUEL CONSUMPTION Miles Per Hour IMP (MPG) x .354 = Kilometers Pe~ Liter (Km/L) Kilometers Per liter (Km/L) x 2.352 = IMP MPG Miles Per Gallons US (MPG) x .425 = Kilometers Per Liter (Km/l} Kilometers Per liter (Km/L) x 2.352 = US MPG

TEMPERATURE Degree Fahrenheit (0 F} = (°C X 1.8) + 32 Degree Celsius (°C) = (°F - 32) x .56

LIQUID WEIGHTS Diesel Oil= 1 US gallon= 7.13 lbs Fresh Water == 1 US g~llon = 8.33 lbs Gasoline'= 1 US gallon= 6.1 lbs Salt Water = 1 US gallon = 8.56 lbs

52

INDEX

AC Generator ............................. .47 Oil Pressure .............................. .40

Assembly ................................. 27 Oil Pump ............................... 28,32

Assembly Procedures ........................ 6 Overspeed Switch ......................... .44

Camshaft ................................. 19 Overspeed Board - By-Passing ............... .49

Carburetor ................................ 35 Parts Identification ........................... 2

Choke Solenoid ........................... .41 Piston Rings ............................... 28

Compression Test .......................... .39 Pump-Raw Water .......................... .36

Cylinder Head Cover ....................... .30 Raw Water Pump ........................... 36

Disassembly Procedures ...................... 6 Repair Limits .............................. 12

Drive Belt Adjustment ...................... .40 Required Tools ............................. 10

Drive Pulley ............................... 31 · Resistance Values ......................... .45

Electronic Governor ....................... .44 Safety Instructions ...................... .I,Il,Ill

Flushing the Cooling System ................. 50 Sealants and Lubricants Chart .................. 7

Engine Adjustments ........................ .39 Shutdown Switches ......................... 44

Engine Disassembly ........................ 15 Siphon-Break ............................. .IV

Engine Tuning .............................. 38 Spark Plugs .............................. .41

Exhaust Valve ............................. 27 Special Tools .............................. 11

Fuel Filter ............................... .33 Specifications .............................. 46

Fuel Pump ................................ 33 Standard and Repair Limits .................. .12

Fuses .................................... 44 Starter Motor .............................. 34

Gasket Information .......................... 6 Testing for Overhaul ........................ .3

Governor-Electric ......................... .43 Testing Oil Pressure ........................ .40

Heat Exchanger ............................ 19 Thermostat ................................ 41

Ignition Timing ............................ 39 Timing Belt Replacement/ Adjustments ......... .43

Inspection and Measurement .................. 20 Torque Specifications ........................ 9

Intake Valve ............................... 27 Troubleshooting Charts ..................... .49 Internal Wiring Diagram .................... .48 Valve Clearance ........................... .42

Lubrication ............................. 51,52 Valve Seat ........ ; ....................... 25

Metric Conversion Chart .................... .48 Water Pump Belt ........................... 39

Oil Clearance .............................. 22 Winding Resistance ........................ .48

Oil Inspection ............................ .32 Wiring Diagram ........................... .45 Zinc Anode .............................. .41


53


SERVICE BULLETIN

DATE: __ 2_4_·A .... p_r-_15 __ BULLETIN NUMBER: 276 ----SUBJECT: Generator Drive Belt Performance

MODELS AFFECTED: 3.5 SBCG and 3.0 BCG Gasoline Generators

DETAIL: Generator drive belt life performance improvements'include a belt tension adjustment change, the addition of a spring spacer, and a n~ idler pulley. 3.5 SBCG generators produced on or after manufacturing date code OD (April 2015) will have these changes. Changes made are enhancements, modification to existing products in the field is not covered under warranty.

Manufacturing of new products includes, for optimum belt break in, adjusting the belt to a dimension of 1" in our assembly process as illustrated below. After the first hour of run time, if necessary, it is adjusted again to 1" prior to releasing the unit for shipment.

Important Note: Maximum performance of the drive belt and prevention of potential failure due to incorrect tension requires the belt be to adjusted to 1" at the recommended 50 hour maintenance service.

Generator drive belts for regular maintenance replacement (part numbers remain the same) will be sold as a kit with instructions that includes the required spring spacer. Replacing the puttey is not required. Initial adjustment of the belt with the spacer installed is 1". After running the unit for 1 hour, varying AC loads in the process, the belt must be adjusted again to 1". After 50 hours run'time, or during the next scheduled service, inspection and adjustment to 1" is required to ensure proper belt tension.

Add 1/8" Spacer Here

WESTERBEKE CORPORATION

Myles St;mdish Industrial Parl<, 150John Hancock Road, Taunton, MA 02780-7319 •Tel: 508.823.7677 •Fax: 508.884.9688 www.westerbeke.com


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